DCA45SSIU2 Rev 7 STD Manual

PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
BRAND SERIES
MODEL DCA-45SSIU2
WHISPERWATT
GENERATOR
(STANDARD)
PARTS LIST NO. M1870300034A

Revision #7 (06/13/07)
To find the latest revision of this

publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Diesel engine exhaust and some of
PAGE 2 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

NOTE PAGE
DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 3

TABLE OF CONTENTS
MQ POWER DCA-45SSIU2 ISUZU 4BG1 ENGINE

AC GENERATOR
GENERATOR Cylinder Head Cover Assembly ......................... 86-87
Cylinder Head Assembly .................................... 88-89
Here's How To Get Help ............................................. 3 Cylinder Block Assembly .................................... 90-91
Table Of Contents ....................................................... 4 Oil Pan and Level Gauge Assembly ................... 92-93
Parts Ordering Procedures ........................................ 5 Camshaft and Valve Assembly ........................... 94-95
DCA-45SSIU2 Specifications...................................... 6 Crankshaft, Piston and Flywheel Assembly ...... 96-97
Dimensions ............................................................... 7-8 Timing Gear and Flywheel Housing Assembly ........ 98-99
Safety Message Alert Symbols ........................... 10-11 Engine Mounting Assembly ............................ 100-101
Rules for Safe Operation ..................................... 12-15 Inlet Manifold Assembly .................................. 102-103
Installation ............................................................ 16-17 Exhaust Manifold Assembly ............................ 104-105
Towing Safety Precautions ....................................... 18 Ventilation Assembly ....................................... 106-107
Trailer Specifications ............................................ 19-21 Water Pump and Corrosion Resistor Assembly ... 108-109
Generator Decals ................................................. 22-23 Thermostat and Housing Assembly ............... 110-111
General Information .................................................. 24 Engine Water Piping Assembly ....................... 112-113
Major Components ................................................... 25 Fan and Fan Belt Assembly ............................ 114-115
Generator Control Panel ........................................... 26 Fuel Injection Assembly .................................. 116-117
Engine Operating Panel ............................................ 27 Fuel Filter and Bracket Assembly .................. 118-119
Output Terminal Panel Familiarization................. 28-30 Fuel Pump and Piping Assembly ................... 120-121
Load Application........................................................ 31 Oil Cooler and Oil Filter Assembly ................. 122-123
Generator Outputs ............................................... 32-33 Oil Pump and Oil Strainer Assembly .............. 124-125
Gauge Reading ......................................................... 33 Oil and Vacuum Piping Assembly ................... 126-127
Output Terminal Panel Connections .................... 34-35 Electrical Control Assembly ............................ 128-129
Pre-setup .............................................................. 36-40 Battery Relay Assembly .................................. 130-131
Generator Start-up Procedure ............................ 41-43 Starter Component Assembly ........................ 132-133
Generator Shut-down Procedure ............................. 44 Inj. Pump Component Assembly .................... 134-137
Maintenance ......................................................... 45-47 Governor Component Assembly .................... 138-141
Trailer Brakes Maintenance ...................................... 48 Feed Pump Assembly ..................................... 142-143
Trailer Maintenance ............................................. 49-50 Misc. Inj. Pump Assembly ............................... 144-145
Trailer Wiring Diagram .............................................. 51 Coupling Assembly ......................................... 146-147
Engine Wiring Diagram ........................................ 52-53 Accelerator Pedal Assembly ........................... 148-149
Generator Wiring Diagram ....................................... 54 Air Duct Assembly ........................................... 150-151
Engine Troubleshooting ....................................... 55-56 Fuel Sedimenter Assembly ............................ 152-153
Generator Troubleshooting ....................................... 57 Clutch Assembly.............................................. 154-155
Explanation of Codes in Remarks Column .............. 58 Switch and Relay Assembly ............................ 156-157
Suggested Spare Parts ............................................ 59
Terms and Condition of Sale Parts .................. 158
COMPONENT DRAWINGS
DRAWINGS
Generator Assembly ........................................... 60-61
Control Box Assembly ......................................... 62-65
Engine & Radiator Assembly .............................. 66-67
Engine Operating Panel Assembly..................... 68-69 Specification and part
NOTE number are subject to
Output Terminal Assembly .................................. 70-71 change without notice.
Battery Assembly ................................................ 72-73
Muffler Assembly ................................................ 74-75
Fuel Tank Assembly ............................................ 76-77
Enclosure Assembly ........................................... 78-81
Rubber Seal Assembly ....................................... 82-83
Name Plate And Decals ...................................... 84-85
PARTS ORDERING PROCEDURES
When ordering parts,

please supply the following information:
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
FedEx or UPS Ground Note: Unless otherwise indicated by customer, all
orders are treated as Standard Orders, and will
FedEx or UPS Second Day or Third Day
ship within 24 hours. We will make every effort to
FedEx or UPS Next Day ship Air Shipments the same day that the order is
Federal Express Priority One received, if prior to 2PM west coast time. Stock
DHL Orders must be so noted on fax or web forms.
Truck
Place Your Parts Order Via Web or Fax

Heres how to get help... For Even More Savings!
Please have the model and serial number on
hand when calling.
Parts Department
800-427-1244 Fax: 800-672-7877 Extra Discounts!
310-537-3700 Fax: 310-637-3284 All parts orders which include complete part numbers
and are received by our automated web parts order
Mayco Parts system, or by fax qualify for the following extra
800-306-2926 Fax: 800-672-7877 discounts:
310-537-3700 Fax: 310-637-3284 Ordered Standard Stock orders
Service Department via orders ($750 list and above)
800-478-1244 Fax: 310-537-4259 Fax 3% 10%
310-537-3700 Web 5% 10%
MQ Power Service Department
800-835-2551 Fax: 310-638-8046 Special freight allowances
310-537-3700 when you order 10 or more
Warranty Department line items via Web or Fax!**
800-421-1244, Ext. 279 Fax: 310-537-1173
310-537-3700, Ext. 279 FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other
Multiquips Main Phone Numbers carrier.
800-421-1244 Fax: 310-537-3927
310-537-3700 NOTE: DISCOUNTS ARE SUBJECT TO CHANGE
MULTIQUIP INC.
18910 WILMINGTON AVENUE Direct TOLL-FREE access
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749 to our Parts Department:
310-537-3700 800-421-1244
FAX: 310-537-3927 Toll-free nationwide 800-427-1244
E-MAIL: mq@multiquip.com
WWW: multiquip.com
DCA-45SSIU2 SPECIFICATIONS
Table 1. Generator Specifications

Model DCA-45SSIU2
Revolving field, self ventilated, open protected type synchronous
Type generator
Armature Connection Star with Neutral Zig Zag
P ha s e 3 S in g le
Standby Output 47.7 KVA (38.2 KW) 27.6 KW
Prime Output 45 KVA (36 KW) 2 6 KW
Voltage 240V or 48 0V 240/120V
Frequency 60 Hz
Speed 1,800 rpm
Power Factor 0.8 1
Aux. AC Power Single Phase, 60 Hz
Voltage 120 VAC
Output 4.8 KW (2.4 KW x 2)
Engine Specifications
Model ISUZU B-4BG1
Type 4 Cycle, water-cooled, direct injection
No. of Cylinders 4 cylinders
Bore x Stroke 4.13 in. x 4.92 in. (105 mm x 125 mm)
Rated Output 55.2 HP/1,800 rpm
Displacement 268 cu. in. (4,392 cc)
Starting Electric
Coolant Capacity 5.3 gal. (20 liters)
Lube Oil Capacity 3.4 gal. (12.9 liters)
2.7 gal. (10.3L)/hr at full load 2.0 gal. (7.6L)/hr at 3/4 load
Fuel Consumption
1.5 gal. (5.7L)/hr at 1/2 load 1.1 gal. (4.2L)/hr at 1/4 load
Battery 12V- 100AH
Fue l #2 Diesel Fuel

DCA-45SSIU2 DIMENSIONS (SIDE AND FRONT)
Figure 1. Dimensions
DCA-45SSIU2 DIMENSIONS (TOP AND REAR)
Figure 2. Dimensions

NOTE PAGE

DCA-45SSIU2 SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS
Safety precautions should be followed at all times when operating Lethal Exhaust Gases
this equipment. Failure to read and understand the Safety
Messages and Operating Instructions could result in injury to
yourself and others. Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
This Owner's Manual has been area or enclosed structure that does not
developed to provide complete provide ample free flow air.
NOTE instructions for the safe and efficient
operation of the MQ Power Model
DCA45SSIU2 WHISPERWATT
GENERATOR.
Explosive Fuel
Before using this GENERATOR, ensure that the operating
individual has read and understands all instructions in this
manual. Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
SAFETY MESSAGE ALERT SYMBOLS overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
The three (3) Safety Messages shown below will inform you sparks from the ignition system. Store fuel in
about potential hazards that could injure you or others. The approved containers, in well-ventilated areas
Safety Messages specifically address the level of exposure to and away from sparks and flames. NEVER
the operator, and are preceded by one of three words: DANGER, use fuel as a cleaning agent.
WARNING, or CAUTION.
Burn Hazards
DANGER: You WILL be KILLED or Engine components can generate extreme heat.
SERIOUSLY injured if you DO NOT follow To prevent burns, DO NOT touch these areas
directions. while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.
WARNING: You CAN be KILLED or
SERIOUSLY injured if you DO NOT follow
directions. Rotating Parts
NEVER operate equipment with covers, or

CAUTION: You CAN be injured if you guards removed. Keep fingers, hands, hair
DO NOT follow directions. and clothing away from all moving parts to
prevent injury.
Potential hazards associated with trowel operation will be
referenced with "Hazard Symbols" which appear throughout
this manual, and will be referenced in conjunction with Safety
"Message Alert Symbols".

DCA-45SSIU2 SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting Respiratory Hazard
ALWAYS place the engine ON/OFF switch

in the OFF position, when the trowel is not
in use. ALWAYS wear approved respiratory protection.
Over Speed Conditions Sight and Hearing hazard
NEVER tamper with the factory settings of the

engine governor or settings. Personal injury ALWAYS wear approved eye and hearing
and damage to the engine or equipment can protection.
result if operating in speed ranges above
maximum allowable.
Equipment Damage Messages
This generator, other property, or

NOTE the surrounding environment could Other important messages are provided throughout this manual
be damaged if you do not follow to help prevent damage to your trowel, other property, or the
instructions. surrounding environment.

DCA-45SSIU2 RULES FOR SAFE OPERATION
CAUTION
CAUTION: NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
Failure to follow instructions in this manual may
lead to serious injury or even death! This these parts to cool before servicing
equipment is to be operated by trained and engine or generator.
qualified personnel only! This equipment is for
industrial use only.
The following safety guidelines should always be used when High Temperatures Allow the engine to cool before
operating the DCA-45SSIU2 Generator: performing service and maintenance functions. Contact
GENERAL SAFETY with hot! components can cause serious burns.
DO NOT operate or service this equipment The engine of this
before reading this entire manual. generator requires an
adequate free flow of
cooling air. NEVER
operate the generator
This equipment should not be operated by persons under 18 in any enclosed or
years of age. narrow area where free
NEVER operate this equipment without proper flow of the air is
protective clothing, shatterproof glasses, steel- restricted. If the air flow
toed boots and other protective devices required is restricted it will
by the job. cause serious damage to the generator or engine and
may cause injury to people. The generator engine gives
off DEADLY carbon monoxide gas.
ALWAYS make sure generator is properly grounded.
NEVER operate this equipment when not feeling NEVER use gas piping as an electrical ground.
well due to fatigue, illness or taking medicine. DO NOT place hands or fingers inside generator engine
compartment when engine is running.
NEVER operate this equipment under the ALWAYS make sure generator installation is accordance with
influence or drugs or alcohol. national and local electrical codes.
ALWAYS have a qualified electrician perform the generator
wiring installation.
NEVER power cables or cords lay in water.
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to NEVER stand in water while AC power from the generator
the equipment and/or injury to user may result. is being transfer to a load.
Manufacture does not assume responsibility for any accident NEVER use a defective or frayed power cable. Check the
due to equipment modifications. cable for cuts in the insulation.
Whenever necessary, replace nameplate, operation and NEVER use a extension cord that is frayed or damaged where
safety decals when they become difficult read. the insulation has been cut.
ALWAYS check the machine for loosened threads or bolts ALWAYS make certain that proper extension cord has been
before starting. selected for the job See Table 5.
NEVER operate the generator in an explosive atmosphere or The electrical voltage required to operate the generator can
near combustible materials. An explosion or fire could result cause severe injury or even death through physical contact
causing severe bodily harm or even death. with live circuits. Turn all circuit breakers OFF before
performing maintenance on the generator.

.
ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and local DANGER
DANGER:
codes before operating generator. Severe injury or death! by
electrocution can result from operating an ungrounded
generator.
ALWAYS be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the Backfeed to a utility system can cause electrocution and or
reach of children. property damage. DO NOT connect to any building's electrical
ALWAYS read, understand, and follow system except through an approved device or after building
procedures in Operators Manual before main switch is opened. ALWAYS have a licensed electrician
attempting to operate equipment. perform the installation
DANGER
DANGER: CAUTION
CAUTION:
Never use damaged or worn cables when DO NOT touch or open any of the below
connecting equipment to the generator. mentioned components while the
Make sure power generator is running. Always allow
connecting sufficient time for the engine and generator
cables are to cool before performing maintenance.
securely connected to the Radiator
generators output terminals, 1. Radiator Cap - Removing the radiator cap while the engine
insufficient tightening of the is hot will result in high pressurized, boiling water to gush
terminal connections may cause out of the radiator, causing severe scalding to any persons
damage to the generator and in the general area of the generator.
electrical shock. WET 2. Coolant Drain Plug - Removing the coolant drain plug
HANDS
DANGER
DANGER: NEVER grab or
while the engine is hot will result in hot coolant to gush out
of the coolant drain plug, therefore causing severe scalding
touch a live to any persons in the general area of the generator.
power cord with 3. Engine Oil Drain Plug - Removing the engine oil drain
wet hands , the POWER plug while the engine is hot will result in hot oil to gush out
CORD
possibility exists (POWER ON)
of the oil drain plug, therefore causing severe scalding to
of electrical shock, electrocution, and even any persons in the general area of the generator.
death!
DANGER
DANGER: Maintenance Safety
NEVER lubricate components or attempt service on a running
machine.
ALWAYS allow the machine a proper

amount of time to cool before servicing.
NEVER touch output terminals during operation. This is

extremely dangerous. ALWAYS stop the machine and Keep the machinery in proper running condition.
place the circuit breaker in the OFF position when contact Fix damage to the machine immediately and always replace
with the output terminals is required. There exists the broken parts.
possibility of electrocution, electrical shock or burn,
which can cause severe bodily harm or even death!

NEVER Run engine without air filter. Severe engine Battery
damage may occur. The battery contains acids that can cause injury to the eyes
ALWAYSservice air cleaner frequently to prevent engine and skin. To avoid eye irritation, always wear safety glasses.
malfunction. Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
ALWAYS disconnect the negative battery terminal before
performing service on the generator.
ALWAYS be sure the operator is familiar with proper safety
precautions when operating the generator set.
ALWAYS store equipment properly when not in use.
DO NOT leave the generator running in the manual mode 1. DO NOT drop the battery. There is the possibility of risk
unattended. that the battery may explode.
DO NOT allow unauthorized people to operate this 2. DO NOT expose the battery to
equipment. open flames, sparks, cigarettes
etc. The battery contains
ALWAYS read, understand, and follow procedures in
combustible gases and liquids. If
Operators Manual before attempting to operate equipment.
these gases and liquids come in
Refer to the Isuzu Engine Owner's Manual for engine contact with a flame or spark, an
technical questions or information. explosion could occur.
3. ALWAYS keep the battery charged. If the battery is not
DANGER: charged a buildup of combustible gas will occur.
Pay close attention to 4. ALWAYS keep battery charging and cables in good working
ventilation when operating condition. Repair or replace all worn cables.
the generator inside 5. ALWAYS recharge the battery in an vented air
tunnels and caves. The environment, to avoid risk of a dangerous concentration
engine exhaust contains noxious elements. of combustible gases.
Engine exhaust must be routed to a 6. In case the battery liquid (dilute sulfuric acid) comes in
ventilated area. contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
Generator Grounding
7. In case the battery liquid (dilute sulfuric acid) comes in
To guard against electrical shock and possible damage to contact with your eyes, rinse eyes immediately with plenty
the equipment, it is important to provide a good EARTH of water, then contact the nearest doctor or hospital, and
ground. seek medical attention.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and specifies Transporting
that the cable ground shall be connected to the grounding ALWAYS shutdown engine before transporting.
system of the building as close to the point of cable entry
as practical. Tighten both fuel tank caps securely.
ALWAYS be sure to use the ground terminal (green wire) If generator is mounted on a trailer, make sure trailer
when connecting a load to the UVWO output terminals. complies with all local and state safety transportation
laws. See next page Towing Safety Precautions for
basic towing techniques.

Towing Safety Precautions Avoid sharp turns.
Trailer should be adjusted to a level position at all times
CAUTION: when towing.
Conform to Department of Transportation Raise and lock trailer wheel stand in up position when
(DOT) Safety Towing Regulations before transporting.
towing generator. DOT Requirements include the following:
z Connect and test electric brake operation.
To reduce the possibility of an accident while transporting z Secure portable power cables in cable tray with
the generator on public roads, always make sure the trailer tie wraps.
that supports the generator and the towing vehicle are in Emergencies
good operating condition and both units are mechanically ALWAYS know the location of the nearest fire extinguisher.
sound.
The following list of suggestions should be used when towing
your generator:
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR) of 6,000 lbs.
ALWAYS know the location of the nearest and first aid kit.
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold. In emergencies always know the location of the
Also check the tire tread wear on both vehicles. nearest phone or keep a phone on the job site.
ALWAYS make sure the trailer is equipped with a "Safety Also know the phone numbers of the nearest
Chain". ambulance, doctor and fire department. This
information will be invaluable in the case of an
ALWAYS attach trailers safety chains to towing vehicle emergency.
properly.
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.
Place chock blocks underneath wheel to prevent rolling,
while parked.
Use the trailers swivel jack to adjust the trailer height to
a level position while parked.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.

DCA-45SSIU2 INSTALLATION
Figure 3. Typical Generator Grounding Application

DCA-45SSIU2 INSTALLATION
Outdoor Installation Generator Grounding
Install the generator in a clear area. Make sure the generator To guard against electrical shock and possible damage to
is on secure level ground so that it cannot slide or shift the equipment, it is important to provide a good EARTH
around. Also install the generator in a manner so that the ground.
exhaust will not be discharged in the direction of nearby Article 250 (Grounding) of the National Electrical Code (NEC)
homes. provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
The installation site must be relatively free from moisture of the building as close to the point of cable entry as
and dust. All electrical equipment should be protected from practical.
excessive moisture. Failure to do will result in deterioration NEC articles 250-64(b) and 250-66 set the following
of the insulation and will result in short circuits and grounding. grounding requirements:
1. Use one of the following wire types to connect the
Foreign materials such as dust, sand, lint and abrasive generator to earth ground.
materials have a tendency to cause excessive wear to a. Copper - 10 AWG (5.3 mm2) or larger.
engine and alternator parts. b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 3) connect the
CAUTION
CAUTION: ground cable between the lock washer and the nut on
Pay close attention to ventilation when the generator and tighten the nut fully. Connect the other
operating the generator inside tunnels and end of the ground cable to earth ground.
caves. The engine exhaust contains 3. NEC article 250-52(c) specifies that the earth ground
noxious elements. Engine exhaust must be rod should be buried aminimum of 8 ft. into the ground.
routed to a ventilated area.
When connecting the generator to

any buildings electrical system
Indoor Installation NOTE ALWAYS consult with a licensed
Exhaust gases from diesel engines are extremely poisonous. electrician.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.

DCA-45SSIU2 TOWING SAFETY PRECAUTIONS
Towing Safety Precautions ALWAYS attach trailers safety chain to bumper of towing
vehicle.
CAUTION
CAUTION: ALWAYS make sure the vehicle and trailer directional,
Check with your local county or state safety backup, brake, and trailer lights are connected and
towing regulations before towing your working properly.
generator. The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
To reduce the possibility of an accident while transporting is not to exceed 15 MPH or less depending on type of
the generator on public roads, always make sure the trailer terrain.
(Figure 4) that supports the generator and the towing vehicle Place chocked blocks underneath wheel to prevent
are in good operating condition and both units are rolling, while parked.
mechanically sound. Place support blocks underneath the trailers bumper to
The following list of suggestions should be used when towing prevent tipping, while parked.
your generator: Use the trailers hand winch to adjust the height of the
Make sure the hitch and coupling of the towing vehicle trailer, then insert locking pin to lock wheel stand in place,
are rated equal to, or greater than the trailer "gross vehicle while parked.
weight rating" (GVWR).
Avoid sudden stops and starts. This can cause skidding,
ALWAYS inspect the hitch and coupling for wear. NEVER or jackknifing. Smooth, gradual starts and stops will
tow a trailer with defective hitches, couplings, chains improve gas milage.
etc.
Avoid sharp turns to prevent rolling.
Check the tire air pressure on both towing vehicle and
Remove wheel stand when transporting.
trailer. Also check the tire tread wear on both vehicles.
DO NOT transport generator with fuel in tank.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 4. Generator with Trailer

DCA-45SSIU2 TRAILER SPECIFICATIONS
CAUTION
CAUTION: 5. Frame Length - Measurement is from fender to fender
ALWAYS make sure the trailer is in good 6. Jack Stand - Trailer support device with maximum pound
operating condition. Check the tires for requirement from the tongue of the trailer.
proper inflation and wear. Also check the 7. Coupler - Type of hitch used on the trailer for towing.
wheel lug nuts for proper tightness. 8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
Explanation of Chart: (175,185,205, etc.). The tire diameter must match the
This section is to provide the user with trailer service and diameter of the tire rim.
maintenance information. The service and maintenance 9. Tire Ply - The tire ply (layers) number is rated in letters;
guidelines referenced in this section apply a wide range of 2-ply,4-ply,6-ply, etc.
trailers. Remember periodic inspection of the trailer will en- 10. Wheel Hub - The wheel hub is connected to the trailers
sure safe towing of the equipment and will prevent damage axle.
to the equipment and personal injury.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
It is the purpose of this section to cover the major mainte- match the size of the tire.
nance components of the trailer. The following trailer com- 12. Lug Nuts - Used to secure the wheel to the wheel hub.
ponents will be discussed in this section: Always use a torque wrench to tighten down the lug nuts.
See Table 17 and Figure 67 or lug nut tightening and
Brakes sequence.
Tires 13. Axle - Indicates the maximum weight the axle can sup-
Lug Nut Torquing port in pounds, and the diameter of the axle expressed
Suspension in inches (see Table 2). Please note that some trailers
Electrical have a double axle. This will be shown as 2-6000 lbs.,
Brake Troubleshooting Tables meaning two axles with a total weight capacity of 6000
Use the following definitions when reading Table 2. pounds.
1. Fuel Cell - Provides an adequate amount of fuel for the 14. Suspension - Protects the trailer chassis from shocks
equipment in use. Fuel cells must be empty when trans- transmitted through the wheels. Types of suspension used
porting equipment. are leaf, Q-flex, and air ride.
2. Braking System - System employed in stopping the 15. Electrical - Electrical connectors (looms) are provided
trailer. Typical braking systems are electric, surge, hy- with the trailer so the brake lights and turn signals can
draulic, hydraulic-surge and air. be connected to the towing vehicle.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the 16. Application - Indicates which units can be employed
maximum number of pounds the trailer can carry, in- on a particular trailer.
cluding the fuel cell (empty).
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).

Table 2. Trailer Specifications

MODEL APPLICATION FU E L BRAKE GVWR FRAME FRAME JACK
C E LL SYSTEM LENGTH WIDTH STAND
TRLR-10W SDW225, NO NO 1900LB S 96" 50" 800LB .
SGW250,TLW- FULL TILT WHEEL
300
TRLR-10 D C A 10, NO NO 1900LB S 96" 50" 800LB .
TLG12, DCA- FULL TILT WHEEL
15
TRLR-10XF DCA10, TLG- 52 GAL NO 1900LB S 96" 50" 800LB .
12, D C A 15, FULL TILT WHEEL
TLW-300
TRLR-225W WELDERS, NO NO 2200LB S 85" 42" 800LB .
D A 7000S S FULL TILT WHEEL
TRLR-BLW400 BLW-400 NO ELECTRIC 2700LB S W/MAST 55" 800LB .
154" (78" FULL TILT WHEEL
W/O 124" TALL)
TRLR-50X DCA-25 NO NO 2700LB S 124" 55" 800LB .
FULL TILT WHEEL
TRLR-50XF DCA-25 41 GAL NO 2700LB S 124" 55" 800LB .
FULL TILT WHEEL
TRLR-70W DCA-45, -60, NO SURGE 7000LB S 186" 77" 2000LB .
70 FLAT PAD
TRLR-70X DCA-45, -60, OPT SURGE 7000LB S 138" 66" 2000LB .
70 FLAT PAD
TRLR-70XF DCA-45, -60, 53 GAL SURGE 7000LB S 138" 66" 2000LB .
70 FLAT PAD
TRLR-100XF DCA-100, 125 150 GAL HYDRAULIC 7000LB S 190" 76" 2000LB .
SURGE FLAT PAD
TRLR-85/125 DCA-85, 100, 145 GAL HYDRAULIC 10000LB S 186" 77" 2000LB .
125 FLAT PAD
TRLR-150XF DCA-150, 180 200 GAL HYDRAULIC 11160LBS 204" 84" 5000 LB .
SURGE FLAT PAD
TRLR-220XF DCA-220 250 GAL HYDRAULIC 14000LB S 222" 83" 5000 LB .
SURGE FLAT PAD
TRLR-300XF DCA-300 250 GAL HYDRAULIC 18000LB S 238" 83" 5000 LB .
SURGE FLAT PAD
TRLR-400XF DCA-400 350 GAL ELECTRIC 18000LB S 238" 83" 5000 LB .
FLAT PAD
TRLR-600XF DCA-600, 800 550 GAL AIR 30000LB S 384" 96" 5000 LB .
FLAT PAD
TRLR-800SX DCA-600, 800 550 GAL AIR 30000LB S 384" 96" 5000 LB .
FLAT PAD

Table 2. Specifications (Con't)

MODEL COUPLER TIRES WHEELS AXLE HUBS SUSPENSION ELECTRICAL
TRLR-10W 2" B A LL C LA S S 175-13C 13"X4.50" 2200# 2X 2 5 LUG 3 LE A F 4 WIRE LOOM
2 ADJUSTABLE W/
4 POLE FLAT
TRLR-10 2" B A LL C LA S S 175-13C 13"X4.5" 2200#2X 2 5 LUG 3 LE A F 4 POLE FLAT
2 ADJUSTABLE
TRLR-10XF 2" B A LL C LA S S 175-13C 13"X4.5" 2200#2X 2 5 LUG 3 LE A F 4 POLE FLAT
2 ADJUSTABLE
TRLR-225W 2" B A LL C LA S S 175-13B 13X4.5" 2200#2X 2 5 LUG Q F LE X 4 POLE FLAT
2 ADJUSTABLE
TRLR-BLW 2" B A LL C LA S S 175-13C 13 X 4.5" 2200#2X 2 5 LUG 3 LE A F 4 POLE FLAT
400 2 ADJUSTABLE
TRLR-50X 2" B A LL C LA S S B78-13LRC 13"X4.50" 3500lbs. 5 LUG 4 LE A F 4 POLE
2-3/8" RUBBER FLAT
TRLR-50XF 2" B A LL C LA S S B78-13LRC 13"X4.50" 3500lbs. 5 LUG 4 LE A F 4 POLE
2-3/8" RUBBER FLAT
TRLR-70W 2" B A LL C LA S S 205-14C 14" X 5" 3500lbs. 5 LUG 5 LE A F 4 POLE
3" ADJUSTABLE BIAS (4) 3" RUBBER FLAT
TRLR-70X 2" B A LL C LA S S 205-14C 14" X 5" 3500lbs 5 LUG 5 LE A F 4 POLE
TRLR-70XF 2" B A LL C LA S S 205-14C 14" X 5" 3500lbs. 5 LUG 5 LE A F 4 POLE
TRLR-100XF ADJUSTABLE 2- 205-15C 14"X5.5" 3500lbs 5 LUG 5 LE A F 4 WIRE LOOM
5/6 OPT 3" EYE BIAS (4) 3"
TRLR-85/125 ADJUSTABLE 2- ST225/75R15D 14"x6" (2)-6000lbs 6 LUG 7 LE A F 4 WIRE LOOM
5/6 OPT 3" EYE RADIAL (4)
TRLR-150XF 3" BALL EYE 750-16 E 16" X 7" (2)-6000lbs 8 LUG 7 LE A F 4 WIRE LOOM
BIAS (4)
TRLR-220XF 3" EYE ST235/85R16E 16" X 7" (2)-7000lbs 8 LUG Q F LE X 4 WIRE LOOM
ADJUSTABLE RADIAL(4)
TRLR-300XF 3" EYE ST235/85R16E 16" X 7" (2)-6000lbs 8 LUG Q F LE X 4 WIRE LOOM
ADJUSTABLE RADIAL(6)
TRLR-400XF 3" EYE ST235/85R16E 16" X 7" (3)-7000lb- 8 LUG Q F LE X 4 WIRE LOOM
ADJUSTABLE RADIAL(6) s.
TRLR-600XF 5TH WHEEL ST215/75R17.5H 16" X 7" (3)-10000l- 8 LUG 7 LE A F 6 WIRE LOOM
RADIAL (8) bs
TRLR-800AR 5TH WHEEL ST215/75R17.5H 16" X 7" (3)-10000l- 8 LUG AIR-RIDE 6 WIRE LOOM
RADIAL (8) bs

DCA-45SSIU2 GENERATOR DECALS
The DCA-45SSIU2 generator is equipped with a number of safety decals. These decals are provided for operator safety
and maintenance information. The illustration below and on the preceding page show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-45SSIU2 GENERATOR DECALS

DCA-45SSIU2 GENERAL INFORMATION
DCA-45SSIU2 FAMILIARIZATION Open Delta Excitation System

Generator The DCA-45SSIU2 generator is equipped with the state of the art
"Open-Delta" excitation system. The open delta system consist of
The MQ Power Model DCA-45SSIU2 (Figure 5) is a 26 kW an electrically independent winding wound among stationary
generator that is designed as a high quality portable (requires windings of the AC output section.
a trailer for transport) power source for telecom sites, lighting
There are four connections of the open delta A, B, C and D. During
facilities, power tools, submersible pumps and other
steady state loads, the power from the voltage regulator is supplied
industrial and construction machinery.
from the parallel connections of A to B, A to D, and C to D.These three
Engine Operating Panel phases of the voltage input to the voltage regulator are then rectified
The Engine Operating Panel is provided with the following: and are the excitation current for the exciter section.
z Tachometer When a heavy load, such as a motor starting or a short circuit occurs,
z Water Temperature Gauge/Lamp the automatic voltage regulator (AVR) switches the configuration of
z Oil Pressure Gauge/Lamp the open delta to the series connection of B to C. This has the effect
z Charging Ammeter Gauge of adding the voltages of each phase ot provide higher excitation to
z Engine Speed Handle the exciter section and thus better voltage response during the
z Pre-Heat Lamp application of heavy loads.
z Panel Light The connections of the AVR to the AC output windings are for
z Panel Light Switch sensing only. No power is required from these windings.
z Ignition/Preheat Switch The open-delta design provides virtually unlimited excitation current,
Generator Control Panel offering maximum motor starting capabilities. The excitation does
The Generator Control Panel is provided with the following: not have a "fixed ceiling" and responds according the demands of
z Output Voltage Adjustment Knob the required load.
z Frequency Meter (Hz) Engine
z AC Ammeter (Amps) The DCA-45SSIU2 is powered by a 4 cycle, water cooled,
z AC Voltmeter (Volts) turbocharged Isuzu 4BG1 diesel engine. This engine is designed
z Ammeter Change-Over Switch to meet every performance requirement for the generator. Reference
z Voltmeter Change-Over Switch Table 1 for engine specifications.
z Voltage Regulator
In keeping with Multiquip's policy of constantly improving its products,
z Over-Current Relay
the specifications quoted herein are subject to change without prior
Output Terminal Panel notice.
The Output Terminal Panel is provided with the following: The basic controls and indicators for the DCA-45SSIU2 generator
z Three 250 VAC output receptacles (CS-6369), 50 amps are addressed on the following pages.
z Three auxilliary circuit breakers, 250V @50 amps Mechanical Governor System
z Two 125 VAC output receptacles, (GFCI), 20 amps The mechanical governor system control the RPM of the engine.
z Two GFCI circuit breakers, 120V@ 20amps When the engine demands increase or decrease, the mechanical
z Five output terminal lugs (3 power) governor system regulates the frequency variation to .5%. The
electronic governor option increases frequency variation to
Control Box 0.25%.
The Control Box is provided with the following: Extension Cables
z 3-Pole, 250 VAC, 110 amp Main Circuit Breaker When electric power is to be provided to various tools or loads at
z Automatic Voltage Regulator some distance from the generator, extension cords are normally
z Current Transformer used. Cables should be sized to allow for distance in length and
z Emergency Relay amperage so that the voltage drop between the generator and point
of use (load) is held to a minimum. Use the cable selection chart
(Table 5 ) as a guide for selecting proper extension cable size.
DCA-45SSIU2 MAJOR COMPONENTS
Figure 5. Major Components
Table 3. Generator Major Components

ITEM NO. DESCRIPTION
1 Muffler Assembly
2 Engine Assembly
3 Generator Assembly
4 Output Terminal Assembly
5 Fuel Tank Assembly
6 Batter y Assembly
7 Generator Control Panel Assembly
8 Engine Operating Panel Assembly

DCA-45SSIU2 GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
The definitions below describe the controls and functions of Located behind the generator control panel is the Generator
the DCA-45SSIU2 "Generator Control Panel " (Figure 6). Control Box. This box contains some of the necessary
1. Main Circuit Breaker This three-pole, 110 amp main electronic components required to make the genertator
breaker is provided to protect the UVWO output function.
terminals from overload. The Control Box is equipped with the following major
2. AC Ammeter Indicates the amount of current the components:
load is drawing from the generator per leg selected by z Over-Current Relay
the ammeter phase-selector switch. z Voltage Rectifer
z Starter Relay
3. Ammeter Change-Over Switch This switch allows z Engine Controller (Computer Controlled)
the AC ammeter to indicate the current flowing to the z Current Transformer
load connected to any phase of the output terminals, or z Voltage Selector Switch
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
Remember the overcurrent
4. Voltmeter Change-Over Switch This switch allows relay monitors the current
the AC voltmeter to indicate phase to phase voltage flowing from the UWVO output
between any two phases of the output terminals or to terminals to the load.
NOTE
be switched off.
In the event of a short circuit or
5. Voltage Regulator Control Allows 15% manual over current condition, it will
adjustment of the generators output voltage. automatically trip the main 250
6. Frequency Meter Indicates the output frequency in amp breaker.
hertz (Hz). Normally 60 Hz 1 Hz . To restore power to the UWVO output terminals, press the
7. AC Voltmeter Indicates the output voltage present reset button on the overcurrent relay and place the main
at the UVWO terminals. circuit breaker in the closed position (ON).

DCA-45SSIU2 ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
The definitions below describe the controls and functions of 7. Starter Switch Four position switch, pre-heat, stop,
the DCA-45SSIU2 "Engine Operating Panel " (Figure 7). run and start. Insert ignition key to start and stop engine.
1. Panel Light - Normally used in dark places or at night. 8. Tachometer Indicates engine speed in RPMs for 60
When activated, panel will luminate. When the generator Hz operation. This meter should indicate 1800 RPMs
is not in use, turn the panel light switch to the OFF when the rated load is applied. In addition a built in hour
position. meter will record the number of operational hours that
2. Panel Light Switch- When activated, will turn on control the generator has been in use.
panel light. 9. Fuel Gauge - Indicates amount of diesel fuel available.
3. Water Temperature Lamp - Indicates that the water 10. Charging Ammeter Gauge Indicates the current
temperature is outside of normal range and will shut being supplied by the engines alternator which provides
down the engine. current for generators control circuits and battery
4. Oil Pressure Lamp - Indicates that the oil pressure is charging system.
too low or high and will shut down the engine. 11. Water Temperature Gauge During normal operation
5. Pre-heat Lamp - This indicates when the engine is this gauge be should read between 165o F to 215o F.
ready for starting during cold weather operating 12. Oil Pressure Gauge Normal operation should be about
conditiions. 25 psi. When starting the generator the oil pressure
6. Engine Speed Handle- This handle will change the may read a bit higher, but after the engine warms up
speed of the engine from high to low. the oil pressure should return to normal.

DCA-45SSIU2 OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization Output Terminal Panel
The Output Terminal Panel (Figure 8) is provided with The Output Terminal Panel (Figure 8) shown below is located
the following: on the right-hand side (left from control panel) of the generator.
Lift up on the cover to gain access to receptacles and terminal
z Three (3) 240V output receptacles, 50 amp lugs.
z Three (3) Circuit Breakers 240V @50 amps
z Two (2) 120V GFCI receptacles, 20 amp Terminal legs O and Ground
z Two (2) GFCI Circuit Breakers 120V@ 20 amps NOTE are considered bonded grounds.
z One Main Circuit Breaker 250V @110 amps
z Five (5) Output Terminal Lugs
Figure 8. Output Terminal Panel

120 VAC GFCI Receptacles Each auxilliary receptacle is protected by a 50 amp circuit
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) breaker. These breakers are located directly above the GFCI
recepacles provided on the output terminal panel. These receptacles. Remember the load output (current) on all three
receptacles can be accessed in any voltage selector switch receptacles is dependent on the load requirements of the
position. Each receptacle is protected by a 20 amp circuit UVWO terminals.
breaker. These breakers are located directly above the GFCI Turn the voltage regulator control knob (Figure 11) on the
receptacles. Remember the load output (current) of both control panel to obtain the desired voltage. Turning the knob
GFCI receptacles is dependent on the load requirements of clockwise will increase the voltage, turning the knob counter-
the UVWO terminals. clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the "Test Button" (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 11. Voltage Regulator Control Knob
Removing the Plastic Face Plate (UVWO Terminals)

The UVWO terminal lugs are protected by a plastic face
plate cover (Figure 12). Un-lock the locking latch, and lift the
terminal cover to gain access to the plastic face plate.
Remove the screws securing the face plate to the terminal
enclosure, then lift the plastic hinged face plate.
After the load wires have been securely attached to the
Figure 9. G.F.C.I. Receptacle UVWO terminals, reinstall the plastic face plate. Place the
terminal cover in the down position and secure the locking
Twist Lock Dual Voltage 120/240 VAC Receptacles latch.
There are three 240 VAC, 50 amp auxilliary twist-lock (CS-
6369) recepacles (Figure 10) provided on the output terminal
panel.These receptacles can only be accessed when the
voltage selector switch is placed in the single-phase 240/
120 position.
Figure 12. Plastic Face Plate (UVWO Terminals)
Figure 10. 240 VAC Twist-Lock

Auxiliary Receptacles

Connecting Loads Over Current Relay
Loads can be connected to the generator by the UVWO terminal An over current relay (Figure 14) is connected to the main
lugs or the convienience receptacles. (See Figure 13). Make circuit breaker. In the event of an overload, both the circuit
sure to read the operation manual before attempting to connect breaker and the over current relay may trip. If the circuit
a load to the generator. breaker can not be reset, the reset button on the over cur-
To protect the UVWO output terminals from overload, a 3- rent relay must be pressed. The over current relay is lo-
pole, 250 amp, main circuit breaker is provided. Make sure cated in the control box.
to switch ALL circuit breakers to the "OFF" position prior to
starting the engine.
Figure 14. Over Current Relay
Figure 13. Connecting Loads

DCA-45SSIU2 LOAD APPLICATION
Single Phase Load Three Phase Load
Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase power
and equipment to insure the wattage, amperage and use the following equation:
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130
150% more wattage than the rating on the nameplate, as Motors and motor-driven
the wattage is influenced by the efficiency, power factor and NOTE equipment draw much greater
starting system of the equipment. current for starting than during
operation.
If wattage is not given on the equipment's
NOTE name plate, approximate wattage may be
An inadequate size connecting cable which cannot carry the
determined by multiplying nameplate
required load can cause a voltage drop which can burn out
voltage by the nameplate amperage.
the appliance or tool and overheat the cable. See Table 5.
z When connecting a resistance load such as an

WATTS l VOLTAGE x AMPERAGE incandescent lamp or electric heater, a capacity of up to
The power factor of this generator is 0.8. See Table 4 below the generating sets rated output (kW) can be used.
when connecting loads.
z When connecting a fluorescent or mercury lamp, a
Table 4. Power Factor By Load capacity of up to the generating sets rated output (kW)
multiplied by 0.6 can be used.
Type Of Load Power Factor
z When connecting an electric drill or other power tools,
Single-phase induction motors 0.4 - 0.75
pay close attention to the required starting current
Electric heaters, incandescent capacity.
lamps 1 .0
Fluorescent lamps, mercury lamps 0.4 - 0.9 When connecting ordinary power tools, a capacity of up to
the generating sets rated output (kW) multiplied by 0.8 can
Electronic devices, communication 1.0
equipment be used.
Common power tools 0.8
CAUTION:
Before connecting this generator to any
Table 5. Cable Selection (60 Hz, Single Phase Operation)
buildings electrical system, a licensed
Load In Watts Maximum Allowable Cable Length
Current in electrician must install an isolation (transfer)
Amperes At 120 At 240
Volts Volts
#10 Wire #12 Wire #14 Wire #16 Wire switch. Serious injury or death may result
2.5 30 0 600 1000 ft. 6 0 0 ft . 375 ft. 250 ft.
without this transfer switch.
5 600 1200 500 ft. 300 ft. 200 ft. 1 2 5 ft .
7.5 900 1800 350 ft. 200 ft. 125 ft. 1 0 0 ft . If 3 load (kVA) is not given on
10 1200 2400 250 ft. 1 5 0 ft . 100 ft.
the equipment nameplate,
NOTE approximate 3 load output
15 1800 3600 150 ft. 100 ft. 65 ft.
maybe determined by multiplying
20 2400 4800 125 ft. 75 ft. 50 ft.
voltage by amperage by 1.732.
CAUTION: Equipment damage can result from low voltage.

DCA-45SSIU2 GENERATOR OUTPUTS
Generator Output Voltages Generator Amperage
A wide range of voltages are available to supply voltage for Tables 7 and 8 describe the generators current output capa-
many different applications. Voltages are selected by using bility for both 1-phase and 3 phase applications.
the voltage selector switch (Figure 15). To obtain some of
the voltages as listed in Table 6 (see below) will require a Table 7. Generator Ampere
fine adjustment using the voltage regulator (VR) control Ratings 1
knob located on the control panel. kW 240V 120V
Voltage Selector Switch 20 83 166
The voltage selector switch (Figure 15) is located above 25 104 208
the UVWO Hard Wire Hook-up Panel. It has been provided 30 225 250
for ease of voltage selection. 35 145 291
40 166 333
45 187 375
50 208 417
60 (Max) 250 500
Table 8. Generator Ampere Ratings 3

kW 208V 240V 480V
20 59 60 30
25 87 75 38
30 104 90 45
Figure 15. Voltage Selector Switch
35 121 105 53
Voltage Selector Switch Locking Button 40 139 120 60
45 156 136 68
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine 50 174 152 76
is running. To lock the voltage selector switch, press and 60 208 181 99
hold the red button located at the bottom of the switch.
CAUTION:
NEVER change the position of the voltage
selector switch while the engine is running.
ALWAYS place circuit breaker in the open
position before selecting voltage.
Table 6. Voltages Available

Three Phase 208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT
(Sw itchable)
Single Phase 120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT
(Sw itchable)

DCA-45SSIU2 GENERATOR OUTPUTS/GAUGE READING
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly re-
lated to the voltage being supplied at either the UVWO ter-
minals or the 3 twist lock auxilliary receptacles. Use this position for
Tables 9 and 10 show what amount of current is available at 3, 208V/1,120V
the GFCI receptacles when the UVWO terminals and twist
lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the recep-
tacles.
Table 9. GFCI Receptacle Load Capability

KVA in Use Available Load Current
(UVWO Terminals) (AMPS)
3 240/480V GFCI Duplex NEMA
5-20R 120V
82 0 Figure 16. Voltage Selector Switch 240/139V Three Phase
Position (for 3, 208V, 120V voltage)
77.8 5 amps per receptacle
Table 10. GFCI Receptacle Load Capability

KW in Use Available Load Current
Twist-Lock (CS6369) (AMPS)
1 240/120V GFCI Duplex NEMA
5-20R 120V
Figure 17. AC Voltmeter Figure 18 AC Voltmeter
60 0 Gauge
Change-Over Switch
58.8 5 amps per receptacle (Volt reading on W-U Lug)
40
55.2 20 amps per receptacle 20 60
0 75
How to Read the Output Terminal Gauge.
The gauge and selector switch on the control panel DO NOT
effect the generator output. They are provided to help ob- A
serve how much power is being supplied, produced at the
UVWO terminals lugs.
When the Voltage selector switch is in the 3,240/139V Figure 19. AC Ammeter Figure 20. AC Ammeter
position (See Figure 16), place the AC Voltmeter Change- Change-Over Switch (Amp reading on U lug)
Over Switch (Figure 17) to the W-U position and the AC
Ammeter Change-Over Switch (Figure 19) to the U or W
position to read the output on the selected leg.
The ammeter and voltmeter
NOTE gauges are only active when the
UVWO terminals are in use.

DCA-45SSIU2 OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages 3 208V/1120V UVWO Terminal Output Voltages
Various output voltages can be obtained using the UVWO 1. Place the voltage selector switch in the 3 240/139
output terminal lugs. The voltages at the terminals are de- position as shown in Figure 24.
pendent on the position of the Voltage Selector Switch and
the adjustment of the Voltage Regulator Control Knob. Use this position for
Remember the voltage selector switch determines the range 3-208 or 1120V.
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
3 240/139 UVWO Terminal Output Voltages Figure 24. Voltage Selector
Switch 3-208V/1-120V
1. Place the voltage selector switch in the 3 240/139 Three-Phase Position
position as shown in Figure 21.
2. Connect the load wires to the UVWO terminals as shown

in Figure 25.
Figure 21. Voltage Selector Switch 240/139V

Three-Phase Position
2. Connect the load wires to the UVWO terminals as shown
in Figure 22.
Figure 25. UVWO Terminal Lugs

3-208V/120V Connections
3. Turn the voltage regulator knob (Figure 26) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 22. UVWO Terminal Lugs

240/139V Three Phase Connections
Figure 26. Voltage Regulator Knob (208V)
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output. To achieve a 3 208V
output the voltage selector
NOTE switch must be in the 3-
240/139 position and the
voltage regulator must be
Figure 23. Voltage Regulator Knob (139V/240V) adjusted to 208V.

DCA-45SSIU2 OUTPUT TERMINAL PANEL CONNECTIONS
3 480/277 UVWO Terminal Output Voltages 1 240V/120V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3 480/277 1. Place the voltage selector switch in the 1 240/120
position as shown in Figure 27. position as shown in Figure 30.
Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position Figure 30. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the UVWO terminals as shown 2. Connect the load wires to the UVWO terminals as shown
in Figure 28. in Figure 31.
Figure 28. UVWO Terminal Lugs Figure 31. UVWO Terminal Lugs
240/139V Three Phase Connections 1-240V/120V Connections
3. Turn the voltage regulator knob (Figure 29) clockwise to 3. Turn the voltage regulator knob (Figure 32) clockwise to
increase voltage output, turn counterclockwise to increase voltage output, turn counterclockwise to
decrease voltage output. decrease voltage output.
Figure 32. Voltage Regulator Knob (1-240/120V)

Figure 29. Voltage Regulator Knob (139V/240V)

DCA-45SSIU2 PRE-SETUP
Circuit Breakers Fuel Check
To protect the generator from an overload, a 3-pole, 110 amp, DANGER:
main circuit breaker is provided to protect the UVW output Fuel spillage on a hot! engine can cause
terminals from overload. In addition two single-pole, 20 amp a fire or explosion. If fuel spillage occurs,
GFCI circuit breakers are provided to protect the GFCI wipe up the spilled fuel completely to
receptacles from overload. Three 50 amp load circuit breakers prevent fire hazards. NEVER! smoke
have also been provided to protect the auxiliary receptacles around or near the generator.
from overload. Make sure to switch ALL circuit breakers to
the "OFF" position prior to starting the engine.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two Refilling the Fuel System
notches (Figure 33) on the dipstick. See Table 11 for proper
selection of engine oil. The DCA45SSJU genset may (if equipped with a trailer or
skid) have a double fuel tank system (Figure 34), which
consists of an internal generator fuel tank, and a trailer
mounted fuel tank. It is also possible the genset can be
equipped with a skid mounted fuel tank (Figure 5). The
skid type fuel system does not use the internal generator
fuel tank.
Use the instructions in this section that applies to your type
Figure 33. Engine Oil Dipstick of fuel tank system.
When checking the engine oil, be sure to check if the oil is ALWAYS fill the fuel tank with clean and fresh #2 diesel
clean. If the oil is not clean, drain the oil by removing the oil fuel. DO NOT fill the fuel tanks beyond their capacities.
drain plug, and refill with the specified amount of oil as outlined Pay attention to the fuel tank capacity when replenishing
in the Isuzu Engine Owner's Manual. Oil should be warm fuel.The fuel tank cap must be closed tightly after filling.
before draining. Handle fuel in a safety container. If the container does not
Other types of motor oils may be substituted if they meet have a spout, use a funnel. Wipe up any spilled fuel
the following requirements: immediately.
z API Service Classification CH-4
z API Service Classification CG-4
z API Service Classification CF-4
z ACEA Specification E3
z ACEA Specification E2
Table 11. Recommended Motor Oil

Temperature Range Type Oil Figure 34. Double Fuel Tank System
77oF and greater

(25oC and greater)
SAE15W-40 or SAE40 WARNING:
32oF to 77oF ONLY properly trained personel who have
SAE 10W-30 or SAE30
(0oC to 25oC) read and understand this section should refill
-22oF to -32oF SAE10W-30 or SAE10
the double fuel tank system.
(-30oC0oC) Use #2 diesel fuel.

CAUTION:
ALWAYS! fill trailer tank first with #2 diesel
fuel, before filling secondary internal tank.
Figure 35. Skid Type Fuel Tank System
Refueling Procedure:
DANGER:
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin
contact and/or inhaling
fumes.
1. Level Tanks make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity. See Figure 36.
WARNING:
Figure 37. Fuel Tank Filling Order
ALWAYS! place trailer on firm level ground
before refueling.
NOTE ONLY! use #2 diesel fuel when

refueling.
Fuel from the secondary inner

NOTE tank will eventually drain into the
Figure 36. Only Fill on Level Ground
primary trailer tank.
2. Trailer Fuel Tank First The trailer fuel tank is the
primary fuel tank and holds a larger capacity of fuel.
The fuel in the trailer will be filtered and sent to the
engine. ALWAYS fill trailer fuel tank (Figure 37) first.

3. NEVER overfill trailer fuel tank It is important to 5. Figure 40 below reflects a full fuel system.
read the trailer fuel gauge when filling trailer fuel tank.
DO NOT wait for fuel to rise in filler neck. See Figure 38.
Figure 38. Full Trailer Tank Figure 40. Full Fuel System
6. Fuel from the engine return line will drain into the secondary
WARNING: internal fuel tank. This fuel will eventually drain into the
primary trailer tank in order to return to the engine.
DO NOT OVER-FILL fuel system. Leave room
for fuel expansion . Fuel expands when heated. WARNING:
It is recommended to only fill the internal secondary
4. Once the trailer tank is full, the secondary inner tank take to 3/4 full in order to allow for fuel return, fuel
expansion, and to avoid spillage. See Figure 41
can be filled (See Figure 39). Notice how the trailer
for fuel expansion.
filler tube level rises when the internal tank is filled.
Figure 41. Fuel Expansion
Figure 39. Filling Secondary Internal Fuel Tank

Coolant (Ethylane Glycol [Green] / Water 50/50 mix)
Use only drinkable tap water. If hard water or water with NOTE When the antifreeze is mixed with
many impurities is used, the inside of the engine and radiator water, the antifreeze mixing ratio
may become coated with deposits and cooling efficiency must be less than 50%.
will be reduced.
An anticorrosion additive added to the water will help prevent Cleaning the Radiator
deposits and corrosion in the cooling system. See the engine The engine may overheat if the radiator fins become
manual for further details. overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
CAUTION: negative battery terminal disconnected.
If adding coolant/antifreeze Air Cleaner
mix to the radiator, DO
NOT remove the radiator Periodic cleaning/replacement is necessary. Inspect it in
cap until the unit has completely cooled. The accordance with the Isusu Engine Owner's Manual.
possibility of hot! coolant exists which can cause severe Fan Belt Tension
burns. A slack fan belt may contribute to overheating, or to
Day-to-day addition of coolant is done from the recovery insufficient charging of the battery. Inspect the fan belt for
tank. When adding coolant to the radiator, DO NOT remove damage and wear and adjust it in accordance with the Isuzu
the radiator cap until the unit has completely cooled. See Engine Owner's Manual.
Table 12 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
The fan belt tension is proper if the fan belt bends 10 to 15
is always between the "H" and the "L" markings.
mm (Figure 42) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator 5.3 Gal. (20 L)
Reserve Tank 0.26 Gal. (1L)
Operation Freezing Weather Figure 42. Fan Belt Tension

When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added. CAUTION
CAUTION:
Table 13. Anti-Freeze Operating Temperatures NEVER! place hands near
the belts or fan while the
Freezing Point Boiling Point generator set is running.
Vol %
Anti-Freeze
C F C F
40 -24 -12 106 222
50 -37 -34 10 8 226

Battery When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
Always maintain battery fluid level between the specified terminals when the ignition switch is in either the Pre-
marks. Battery life will be shortened, if the fluid level are not Heat, RUN, or START position. ALWAYS make sure
properly maintained. Add only distilled water when that the ignition switch is in the STOP position when
replenishment is necessary. connecting the battery.
DO NOT over fill. Check to see whether the battery cables 2. Place a small amount of battery terminal treatment
are loose. Poor contact may result in poor starting or compound around both battery terminals. This will ensure
malfunctions. Always keep the terminals firmly tightened. a good connection and will help prevent corrosion around
Coating the terminals with an approved battery terminal the battery terminals.
treatment compound. Replace battery with only
recommended type battery. The battery type used in this If the battery cable is connected
generator is BCI Group 27. incorrectly, electrical damage to the
NOTE generator will occur. Pay close
The battery is sufficiently charged if the specific gravity of
attention to the polarity of the
the battery fluid is 1.28 (at 68 F). If the specific gravity
battery when connecting the
should fall to 1.245 or lower, it indicates that the battery is
battery.
dead and needs to be recharged or replaced.
Battery Cable Installation CAUTION
CAUTION:
ALWAYS be sure the battery cables (Figure 43) are properly
connected to the battery terminals as shown below. The Inadequate battery connections may cause
RED cable is connected to the positive terminal of the battery, poor starting of the generator, and create
and the BLACK cable is connected to the negative terminal other malfunctions.
of the battery.
CAUTION Alternator
CAUTION:
The polarity of the alternator is negative grounding type. When
ALWAYS disconnect the negative an inverted circuit connection takes place, the circuit will be
terminal FIRST and reconnect in short circuit instantaneously resulting the alternator failure.
negative terminal LAST. DO NOT put water directly on the alternator. Entry of water
into the alternator leads an electrolyte corrosion causing an
alternator failure.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
Figure 43. Battery Connections
wear and tightness. Tighten all hose clamps and check hoses
for leaks.
If any hose (fuel or oil) lines are defective replace them
immediately.

DCA-45SSIU2 GENERATOR START-UP PROCEDURE
WARNING:
The engine's exhaust contains harmful
emissions. ALWAYS have adequate
ventilation when operating. Direct exhaust
away from nearby personnel.
BEFORE STARTING
Generator and Control Panel
CAUTION:
NEVER! manually start the engine with the Figure 45. Load Connections
main, GFCI or auailliary circuit breakers in
the ON (closed) position. 3. Close all engine enclosure doors (Figure 46).
1. Be sure and place the main, G.F.C.I. and aux. circuit

breakers (Figure 44) in the OFF position prior to starting
the engine.
Figure 46. Engine Enclosure Doors
4. Place the voltage selector switch in the desired voltage

Figure 44. Main, Aux. and GFCI position (Figure 47).
Circuit Breakers
2. Connect the load to the UVWO terminals or auxiliary
receptacles as shown in Figure 45. These load
connection points can be found on the output terminal
panel. To gain access to the UVWO terminals or other
power receptacles, unlock the access cover and lift the
door.
The UVWO terminals are protected by a plastic cover,
remove this cover to gain access to the terminals. Figure 47. Voltage Selector Switch
Tighten terminal nuts securely to prevent load wires from
slipping out.

5. Push the engine throttle control lever inward (Figure 48) 10. The generator's frequency meter (Figure 52) displays
to the LOW position. the 60 cycle output frequency in HERTZ.
Figure 48. Engine Throttle Control Lever (Low)

Figure 52. Frequency Meter (Hz)
6. Preheat the engine glow plugs by turning the ignition
11. The generator's voltage meter (Figure 53) displays the
key (Figure 49) to the PRE-HEAT position.
120 VAC in VOLTS. If the voltage is not within the specified
frequency tolerance,
Figure 49. Ignition Switch (Pre-Heat Position) Figure 53. AC Voltmeter

7. When the preheat lamp luminates (Figure 50), turn the
ignition key to the START position. Once the engine 12. Use the voltage adjustment control knob (Figure 54) to
starts, release the ignition key and allow it to return to increase or decrease the desired voltage.
the OPERATION position (Figure 49).
Figure 50. Pre-Heat Indicator Lamp Figure 54. Voltage Adjust Control Knob
8. Let the engine idle for 3-5 minutes, listen and check for 13. The ammeter (Figure 55) will indicate zero amps with no
any abnormal sounds or smells. Check for fuel leaks, load applied. When a load is applied, this meter will
and noises that would associate with a loose cover or indicate the amount of current that the load is drawing
harware. If any of the above mentioned conditions exists, from the generator.
shut-down the engine and correct the problem.
9. If the engine is running smoothly with no problems, pull
and place the engine throttle lever (Figure 51) in the
HIGH position.
Figure 55. Ammeter (No Load)
Figure 51. Engine Throttle Control Lever (High)

14. The engine oil pressure gauge (Figure 56) will indicate 17. Turn the main, GFCI, and aux. circuit breakers to the
the oil pressure (kg/ cm2) of the engine. Under normal ON position (Figure 59).
operating conditions the oil pressure is approximately
Figure 56. Oil Pressure Gauge
15. The coolant temperature gauge (Figure 57) will indicate

the coolant temperature. Under normal operating Figure 59. Main, AUX. and GFCI
conditions the coolant temperature is between 165 and Circuit Breakers (ON)
215 degrees Fahrenheit.
18. Observe the generator's ammeter (Figure 60) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if the load is in use.
Figure 57. Coolant Temperature Gauge
16. The tachometer (Figure 58) will indicate the speed of the
engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
Figure 60. Ammeter (Load)
RPMs.
19. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 58. Engine Tachometer

DCA-45SSIU2 GENERATOR SHUT-DOWN PROCEDURE
NORMAL SHUT-DOWN EMERGENCY SHUT-DOWN SHUTDOWN
To shutdown the generator, use the following procedure: 1. To shut-down the engine in the event of an emergency,
1. Switch the MAIN, AUX and GFCI circuit breakers switch the MAIN, GFCI and LOAD (Figure 61) circuit
(Figure 61) to the OFF position (no load). breakers to OFF position.
2. Turn the ignition switch key to the STOP position.
Figure 61. Main, AUX. and GFCI

Circuit Breakers (OFF)
2. Push the engine throttle control lever inward (Figure 62)

to the LOW position.
Figure 62. Engine Throttle Control Lever (Low)
3. Let the engine cool by running it for 3-5 minutes with no

load applied (circuit breakers in the off position).
4. Place the ignition switch (Figure 63) in the STOP position,
remove the key and store in a safe place.
Figure 63. Ignition Switch (Off Position)
5. Remove all loads from the generator.

DCA-45SSIU2 GENERATOR/ENGINE MAINTENANCE
10 Hrs
TABLE 14. INSPECTION/MAINTENANCE DAILY
250 Hrs 500 Hrs 1000 Hrs
Check Engine Fluid Levels X

Check Air Cleaner X
Check Battery Acid Level X
Check Fan Belt Condition X
Check for Leaks X
Check for Loosening of Par ts X
Replace Engine Oil and Filter *1 X
Clean Air Filter X
Drain Bottom of Fuel Tank X
ENGINE
Clean Unit, Inside and Outside X
Change Fuel Filter *2 X
Clean Radiator and Check Coolant Protection Level X
Test Fuel Injection Nozzle X
Replace Air Filter Element X
Check all Hoses and Clamps X
Check Valve Clearance X
Check Injection Nozzle X X
Clean Inside of Fuel Tank X
GENERATOR Measure Insulation Resistance Over 3M ohms X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Replace fuel filter at 250 Hours, first time only.
General Inspection Service Daily

Prior to each use, the generator should be cleaned and inspected If the engine is operating in very dusty or dry grass conditions, a
for deficiencies. Check for loose, missing or damaged nuts, bolts clogged air cleaner will result. This can lead to a loss of power,
or other fasteners. Also check for fuel, oil, and coolant leaks. excessive carbon buildup in the combustion chamber and high
fuel consumption. Change air cleaner more frequently if these
Engine Side (Refer to the Engine Instruction Manual)
conditions exists.
Air Cleaner
Fuel Addition
Every 50 hours: Remove air cleaner element and clean the heavy
duty paper element with kerosene, or foam element with liquid Add diesel fuel (the grade may vary according to season and
detergent and hot water. Wrap foam element in a cloth and locations). Always pour through the mesh filter.
squeeze dry. For heavy duty paper element, wipe excess
kerosene with towel. Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate in
Air Cleaner with Dust Indicator the bottom of the tank. Occasionally remove the drain cock and
This indicator is attached to the air cleaner. When the air cleaner drain the contents. During cold weather, the more empty volume
element is clogged, air intake restriction becomes greater and inside the tank, the easier it is for water to condense. This can be
the dust indicator signal shows RED meaning the element reduced by keeping the tank full with diesel fuel.
needs changing. After changing the air element, press the dust
indicator button to reset the indicator.

DCA-45SSIU2 MAINTENANCE
Air Removal Flushing Out Radiator and Replacing Coolant
If air enters the fuel injection system of a diesel engine, z Open both cocks located at the crankcase side and at
starting becomes impossible. After running out of fuel, or the lower part of the radiator and drain coolant. Open the
after disassembling the fuel system, bleed the system radiator cap while draining. Remove the overflow tank
according to the following procedure. and drain.
To restart after running out of fuel, turn the switch to the z Check hoses for softening and kinks. Check clamps for
ON position for 15-30 seconds. Try again, if needed. This signs of leakage.
unit is equipped with an automatic air bleeding system. z Flush the radiator by running clean tap water through
Cleaning the Fuel Strainer radiator until signs of rust and dirt are removed. DO NOT
clean radiator core with any objects, such as a
Clean the fuel strainer if it contains dust or water. Remove screwdriver.
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not z Tighten both cocks and replace the overflow tank.
leak. Check the fuel strainer every 200 hours of operation or z Replace with coolant (Table 12 for correct mixture).
once a month. z Close radiator cap tightly.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
CAUTION:
fuel tank is filled. Insufficient oil may cause severe damage Allow engine to cool when flushing out
to the engine. Make sure the generator is level. The oil level radiator. Flushing the radiator while hot!
must be between the two notches on the dipstick as shown will damage radiator.
in Figure 33.
Replacing Oil Filter Generator Storage
Detach the oil filter by loosening center bolt and remove For longe term storage of the generator the following is
the element together with the filter body. recommended:
Apply a film of oil to the gasket for the cartridge. z Fill the fuel tank completely. Treat with a fuel stabilizer
Install the filter body together with the element and fix if necessary.
them by tightening the center bolt. z Completely drain the oil from the crankcase and refill if
After the oil cartridge has been replaced, the engine oil necessary with fresh oil.
will drop slightly. Run the engine for a while and check z Clean the entire generator, internal and external.
for leaks before adding more oil if needed. Clean z Cover the generating set and store in a clean, dry place.
excessive oil from engine.
z Disconnect the battery.
Replacing Fuel Filter z Make sure engine coolant is at proper level.
Replace the fuel filter cartridge with new one every 400 z If generator is mounted on a trailer, jack trailer up and
hours or so. place on block so tires do touch the ground or remove
Loosen the drain plug at the lower top of the fuel filter. tires.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Vent any air.
Feed Pump Strainer Cleaning
The strainer is incorporated in the feed pump inlet side joint
bolt. Clean the strainer with compressed air and rinse it in
the fuel oil.

DCA-45SSIU2 MAINTENANCE
Jacket Water Heater and Internal Battery Charger If the generator will be used daily, the battery should normally
120 VAC Input Plugs (OPTIONAL) not require charging. If the generator will be idle (not used)
This generator is equipped with two 120 VAC, 20 amp input for long periods of time, apply power to the battery charger
plugs located on the output terminal panel. plug via commercial power using an power cord of adequate
size.
The purpose of these plugs is to provide power via
commercial power to the jacket water heater and internal
battery charger. To ensure adequate starting
capability, always have power
These plugs will ONLY function when commercial power has NOTE applied to the generator's
been supplied to them (Figure 64). To apply commercial power
internal battery charger.
to these plugs, a power cord of adequate size will be required
(See Table 5).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times. To
apply power to the jacket water heater, simply apply power
to the jacket water heater plug via commercial power using
an power cord of adequate size.
Figure 64. DCA-45SIU2 Battery Charger &

Jacket Water Heater Power Connections

DCA-45SSIU2 TRAILER BRAKES MAINTENANCE
Brakes Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 65) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should be
every 3,000 miles. If driving over rough terrain, inspect the periodically checked for cracks, kinks, or blockage.
brakes more frequently.
Figure 74 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the Figure 65. Hydraulic Brake Components
star wheel of the adjuster assembly to expand the brake
shoes. Actuator
5. Adjust the brake shoes outward until the pressure of the Hydraulic surge braking requires the installation of an actuator
lining against the wheel drum makes the wheel difficult at the tongue of the trailer. Remember the surge or push of
to turn. the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
6. Adjust, rotate the star wheel in the opposite direction
pushes against the tow vehicle the actuator telescopes
until the wheel rotates freely with slight lining drag.
together and applies force to the master cylinder, supplying
7. Replace the adjusting hole cover and lower the trailer to hydraulic pressure to the trailer brakes.
the ground.
Periodically check and test the surge actuator to make
8. Repeat steps 1 through 7 on the remaining brakes. sure that it is functioning correctly. Never use an undersize
actuator.
Table 15. Hydraulic Brake Troubleshooting
Symptom Possible Cause Solution
No Brakes Brake line broken or kinked? Repair or replace.
Brake lining glazed? Reburnish or replace.
Trailer overloaded? Correct weight.
Weak Brakes or Brakes Pull to
Brake drums scored or grooved? Machine or replace.
One Side
Tire pressure correct? Inflate all tires equally.
Tires unmatched on the same axle? Match tires.
Brake components loose, bent or broken? Replace components.
Locking Brakes
Brake drums out-of-round? Replace.
System lubricated? Lubricate.
Noisy Brakes
Brake components correct? Replace and correct.
Brake lining thickness incorrect or not Install new shoes and
adjusted correctly? linings.
Dragging Brakes
Replace rubber par ts
Enough brake fluid or correct fluid?
fill with dot 4 fluid.

DCA-45SSIU2 TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts Suspension
Tires and wheels are a very important and critical The leaf suspension springs and associated components
components of the trailer. When specifying or replacing the (Figure 66) should be visually inspected every 6,000 miles
trailer wheels it is important the wheels, tires, and axle are for signs of excessive wear, elongation of bolt holes, and
properly matched. loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
CAUTION: as detailed in Table 17.
DO NOT attempt
to repair or modify
a wheel. DO NOT
install in inner
tube to correct a leak through the rim. If the
rim is cracked, the air pressure in the inner tube may cause
pieces of the rim to explode (break off) with great force and
cause serious eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot!. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear. Figure 66. Major Suspension Components
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems. Table 17. Suspension Torque Requirements
Item Torque (Ft.-Lbs.)
TABLE 16 TIRE WEAR TROUBLESHOOTING
WEAR PATTERN CAUSE SOLUTION 3/8" U-BOLT MIN-30 MAX-35
Adjust pressure to
Center Wear Over Inflation. particular load per tire 7/16" U-BOLT MIN-45 MAX-60
manufacturer.
Adjust pressure to 1/2" U-BOLT MIN-45 MAX-60
Edge Wear Under Inflation. particular load per tire
manufacturer.
Make sure load does SHACKLE BOLT SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
Loss of camber
Side Wear not exceed axle rating. SPRING EYE BOLT LOCKING NUTS OR COTTER PINS ARE PROVIDED
or overloading.
Align wheels. TO RETAIN NUT-BOLT ASSEMBLY.
Toe Wear Incorrect toe-in. Align wheels.
SHOULDER TYPE MIN-30 MAX-50
Cupping Out-of-balance. Check bearing adjustment SHACKLE BOLT
and balance tires.
Wheel lockup & Avoid sudden stops when

Flat Spots tire skidding. possible and adjust brakes.
CAUTION:
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.

DCA-45SSIU2 TRAILER MAINTENANCE
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 67. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements

Wheel Size First Pass Second Pass Third Pass
FT-LBS FT-LBS FT-LBS
12" 20-25 35-40 50-65
13" 20-25 35-40 50-65
14" 20-25 50-60 90-120
15" 20-25 50-60 90-120
16" 20-25 50-60 90-120
NEVER use an pneumatic air

NOTE gun to tighten wheel lug nuts.
Figure 67. Wheel Lug Nuts Tightening Sequence

DCA-45SSIU2 TRAILER WIRING DIAGRAM
Figure 68. Trailer/Towing Vehicle Wiring Diagram

DCA-45SSIU2 ENGINE WIRING DIAGRAM
Figure 69. Engine Wiring Diagram

DCA-45SSIU2 ENGINE WIRING DIAGRAM
Figure 69. Engine Wiring Diagram(Continued)

DCA-45SSIU2 GENERATOR WIRING DIAGRAM
Figure 70. Generator Wiring Diagram

DCA-45SSIU2 TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper diagnosis based on the Engine Troubleshooting (Table 19). If
handling and maintenance inspections, but in the event of a the problem cannot be remedied, consult our company's
breakdown, use the tables shown for business office or service plant.
TABLE 19. ENGINE TROUBLESHOOTING

SYMPTOM POSSIBLE PROBLEM SOLUTION
No fuel? Replenish fuel.
Air in the fuel system? Bleed system.
Water in the fuel system? Remove water from fuel tank.
Fuel pipe clogged? Clean fuel pipe.
Fuel filter clogged? Clean or change fuel filter.

Excessively high viscosity of
fuel or engine oil at low Use the specified fuel or engine oil.
temperature?
Fuel with low cetane number? Use the specified fuel.
Fuel leak due to loose injection

pipe retaining nut? Tighten nut.
Engine does not star t. Incorrect injection timing? Adjust.
Fuel cam shaft worn? Replace.
Injection nozzle clogged? Clean injection nozzle.
Injection pump malfunctioning? Repair or replace.
Seizure of crankshaft, camshaft, Repair or replace.

piston, cylinder liner or bearing?
Compression leak from Replace head gasket, tighten cylinder head bolt, glow plug and
cylinder? nozzle holder.
Improper valve timing? Correct or replace timing gear.
Piston ring and liner worn? Replace.
Excessive valve clearance? Adjust.
Star ter malfunctioning? Repair or replace.

Star ter does not run.
Wiring disconnected? Connect wiring.

DCA-45SSIU2 TROUBLESHOOTING (ENGINE)
TABLE 19. ENGINE TROUBLESHOOTING (CONTINUED)

Fuel filter clogged or dir ty? Clean or change.
Air cleaner clogged? Clean or change.
Fuel leak due to loose injection

pipe retaining nut? Tighten nut.
Injection pump malfunctioning? Repair or replace.

Engine revolution is not smooth.
Incorrect nozzle opening
pressure? Adjust.
Injection nozzle stuck or

clogged? Repair or replace.
Fuel over flow pipe clogged? Clean.
Governor malfunctioning? Repair.
Excessive engine oil? Reduce to the specified level.
Piston ring and liner worn or Repair or replace.

Either white or blue exhaust gas stuck?
is observed.
Incorrect injection timing? Adjust.
Deficient compression? Adjust top clearance.
Overload? Lessen the load.
Low grade fuel used? Use the specified fuel.

Either black or dark gray Fuel filter clogged? Clean or change.
exhaust gas is observed.
Air cleaner clogged? Clean or change.
Deficient nozzle injection? Repair or replace the nozzle.
Incorrect injection timing? Adjust.
Engine's moving par ts seem to

be seizing? Repair or replace.
Deficient output. Uneven fuel injection? Repair or replace the injection pump.
Deficient nozzle injection? Repair or replace the nozzle.
Replace head gasket, tighten cylinder head bolt, glow plug and
Compression leak? nozzle holder.

DCA-45SSIU2 TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 20) . If the
problem cannot be remedied, consult our company's business office or service plant.
TABLE 20. GENERATOR TROUBLESHOOTING

No Voltage Output AC Voltmeter defective? Check output voltage using a voltmeter.
Is wiring connection loose? Check wiring and repair.
Is AVR defective? Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Low Voltage Output Is engine speed correct? Turn engine throttle lever to "High".
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
High Voltage Output Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Circuit Breaker Tripped Shor t Circuit in load? Check load and repair.
Over current? Confirm load requirements and reduce.
Defective circuit breaker? Check and replace.
Over current Relay actuated? Confirm load requirement and replace.

EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts book.
Items Found In the Remarks Column

Serial Numbers-Where indicated, this indicates a serial number
range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model number
or model number variant.
Items Found In the Items Number Column

All parts with same symbol in the number column, , #, +, %,
or <, belong to the same assembly or kit
*
If more than one of the same

NOTE reference number is listed, the last
one listed indicates newest (or
latest) part available.
NOTE The contents of this catalog are

subject to change without notice.

DCA-45SSIU2 SUGGESTED SPARE PARTS
DCA-45SSIU2 W/ISUZU 4BG1 DIESEL ENGINE

1 TO 3 UNITS
Qty. P/N Description
1 ......... 0601820671 .............. AUTOMATIC VOLTAGE REGULATOR
1 ......... 0601840073 .............. RHEOSTAT VOLTAGE REGULATOR
1 ......... 0601840121 .............. KNOB RHEOSTAT
1 ......... M1310500403 ........... RADIATOR HOSE
1 ......... M1310500303 ........... RADIATOR HOSE
5 ......... 8943212191 .............. OIL FILTER
5 ......... X132400240 ............. FUEL FILTER
5 ......... 0602046368 .............. AIR ELEMENT
3 ......... 0602042420 .............. FUEL TANK, IN-LINE FILTER
1 ......... 0602122272 .............. UNIT, OIL PRESSURE
1 ......... 0602123260 .............. UNIT WATER TEMPERATURE
2 ......... 0601810245 .............. BULB, ALARM LAMP
1 ......... 8970208220 .............. FAN BELT
1 ......... 1823100080 .............. STARTER SWITCH
3 ......... KEYISUZUF ............. KEY, STARTER SWITCH
2 ......... 0601808803 .............. CIRCUIT BREAKER, GF-530EM 125V 20A
3 ......... 0601808804 .............. CIRCUIT BREAKER, CS6369 250V 50A
4 ......... 9825139289 .............GLOW PLUG
1 ......... 47130106 .................. KNOB, SELECTOR SWITCH
1 ......... 5825500422 .............. EMERGENCY RELAY
1 ......... 0605505070 .............. FUEL CAP
Part number on this Suggested Spare

NOTE Parts list may supercede/replace the
P/N shown in the text pages of this book.

DCA-45SSIU2 GENERATOR ASSY.
GENERATOR ASSY.

DCA-45SSIU2 GENERATOR ASSY.
GENERATOR ASSY.
NO. PART NO. ITEM QTY. REMARKS
1 8051000042 ROTOR ASSY. ..................................... 1 ............INCLUDES ITEMS W/
1-1 FIELD ASSY. 1
*
*
1-2 8051070003 FAN 1
*
1-3 0012110035 HEX. HEAD BOLT 8
*
1-4 030210250 LOCK WASHER ................................... 8 ............REPLACES 0042510000
*
1-5 8041611004 COUPLING DISK 4
*
1-6 8041015003 BALANCING PLATE 1
*
1-7 0105091025 HEX. HEAD BOLT ................................ 6 ............REPLACES 0010310025
*
1-8 0042510000 LOCK WASHER 6
*
1-9 8001026013 SET PLATE, RECTIFIER 1
*
1-10 0601821349 RECTIFIER .......................................... 2 ............PT 3610
*
1-11 0601822601 SURGE ABSORBER ........................... 1 ............ERZ-M14JK621A
*
1-12 8001020004 INSULATOR WASHER 1
*
1-13 8001020504 INSULATOR WASHER 1
*
1-14 011008020 HEX. HEAD BOLT ................................ 4 ............REPLACES 0010108020
*
1-15 0040080000 LOCK WASHER 4
*
1-16 0601000209 BALANCING WEIGHT KIT 1
*
1-17 0071906310 BEARING ............................................. 1 ............6310 DDU C3
2
* 8051614003 COUPLING RING ................................ 1 ............REPLACES M1163400203
3 0801831704A REAMER BOLT .................................... 2 ............REPLACES M9200100204
4 0012810030 HEX. HEAD BOLT 7
5 030210250 LOCK WASHER ................................... 2 ............REPLACES 0042510000
6 8051340503 STRATOR ASSY. 1
7 0845041904 GROMMET 2
8 8041315202 END BRACKET 1
9 8041350013 FIELD ASSY. EXCITER 1
10 0010308065 HEX. HEAD BOLT 4
11 0042608000 LOCK WASHER 4
12 031108160 PLAIN WASHER ................................... 4 ............REPLACES 0041208000
13 0010108030 HEX. HEAD BOLT 6
14 0040008000 LOCK WASHER 6
16 8041310024 COVER, BEARING 1
17 8041312014 GASKET, BEARING 1
18 8041331014 COVER, END BRACKET 1
19 0017106012 HEX. HEAD BOLT ................................ 8 ............REPLACES 0017106012
20 8001333003 COVER, END BRACKET 1
21 0010106030 HEX. HEAD BOLT 2
22 0040006000 LOCK WASHER 2
24 0105091025 HEX. HEAD BOLT ................................ 6 ............REPLACES 0010310025
25 0042510000 LOCK WASHER 6
26 8051332014 COVER, FAN 1
27 0605000010 RUBBER SUSPENSION 2
28 0030012000 HEX. NUT 2
28 0040012000 LOCK WASHER 2

DCA-45SSIU2 CONTROL BOX ASSY.
CONTROL BOX ASSY.

DCA-45SSIU2 CONTROL BOX ASSY.
CONTROL BOX ASSY.
1 M1213000402 CONTROL BOX ................................................... 1 ................. S/N7500646 TO 7200915
1 M1213000412 CONTROL BOX ................................................... 1 ................. S/N7200916 TO 7200995
1 M1213000422 CONTROL BOX ................................................... 1 ................. S/N7200996~
2 0601808811 CIRCUIT BREAKER, KAF3611010213P110A 1
3 0027105080 MACHINE SCREW 4
4 0601823863 RELAY UNIT ........................................................ 2 ................. MSA9013A
5 0021304015 MACHINE SCREW .............................................. 4 ................. REPLACES 0027104015
6 0601820671 AUTOMATIC VOLTAGE REGULATOR ................. 1 ................. NTA-5A-2DB
7 0027105010 MACHINE SCREW .............................................. 4 ................. S/N7200646 TO 7201105
7 0027105015 MACHINE SCREW .............................................. 4 ................. S/N7201106~
8 0601806116 CURRENT TRANSFORMER .............................. 3 ................. 812-943 75/5A
10 0601820845 OVER CURRENT RELAY .................................... 1 ................. LR2D1308
11 0601820846 OVER CURRENT RELAY .................................... 1 ................. LR7D1064
12 M1260600004 FITTING BRACKET ............................................. 1 ................. S/N7200646 TO 7200996
13 0030004000 HEX. NUT ............................................................. 2 ................. REPLACES 0207004000
14 0021004010 MACHINE SCREW .............................................. 2 ................. S/N7200646 TO 7200996
15 M1213500303 CONTROL BOX COVER 1
16 011106015 HEX. HEAD BOLT ................................................ 4 ................. REPLACES 0016906015
17 M1923100004 SELECTOR SWITCH .......................................... 1 ................. VY-40
17A 47130106 KNOB, SELECTOR SWITCH 1
18 M1213600104 SWITCH BRACKET ............................................. 1 ................. S/N7200646 TO 7200915
18 M1213600114 SWITCH BRACKET ............................................. 1 ................. S/N7200916~
21 M1213600004 SWITCH COVER ................................................. 1 ................. S/N7200646 TO 7200915
21 M1213600014 SWITCH COVER ................................................. 1 ................. S/N7200916~
22 011106015 HEX. HEAD BOLT ................................................ 4 ................. S/N7200646 TO 7200870;
................................................................................................... REPLACES 0016906015
22 011106015 HEX. HEAD BOLT ................................................ 3 ................. S/N720871~; REPLACES
................................................................................................... 0016906015
23 0040506000 TOOTHED WASHER 1
24 M1223000303 CONTROL PANEL 1
25 0601807630 FREQUENCY METER, 264250DJDJ9 ............... 1 ................. S/N7200646 TO 7202360
25 0601807641 FREQUENCY METER, FCF6 45-65Hz 240V .... 1 ................. S/N7202361~

DCA-45SSIU2 CONTROL BOX ASSY. (CONT.)
CONTROL BOX ASSY. (CONT.)

DCA-45SSIU2 CONTROL BOX ASSY. (CONT.)
CONTROL BOX ASSY. (CONT.)
26 0601808950 AC AMMETER, 260240LSPB1 ................. 1 .......... S/N7200646 TO 7202360
26 0601808986 AC AMMETER, ACF60-75A,0-150A/5A ... 1 .......... S/N7202361~
27 0601801040 CHANGE-OVER SWITCH, AMMETER .... 1 .......... SL-2AS
28 0601806813 AC VOLTMETER, 260244SJSJ1 .............. 1 .......... S/N7200646 TO S/N7202360
28 0601806859 AC VOLTMETER, SCF6 0-600V .............. 1 .......... S/N7202361~
29 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1 .......... SL-2VS
30 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ..... 1 .......... RA20A2SE102BJ 2W 1kOHM
31 0601840121 KNOB 1
32 M1223100004 STOPPER 1
33 0027105015 MACHINE SCREW ................................... 2 .......... S/N7200646 TO 7201195
33 0027105010 MACHINE SCREW ................................... 2 .......... S/N7201196~
34 0027105015 MACHINE SCREW ................................... 4 .......... S/N7200646 TO 7201195
34 0027105010 MACHINE SCREW ................................... 4 .......... S/N7201196~
35 M9220100004 SET SCREW 1
36 0080200007 SNAP RING 1
37 5825500422 EMERGENCY RELAY - 12 VOLT ............. 1 .......... REPLACES 0602200409
37 1825500732 EMERGENCY RELAY - 24 VOLT ............. 1
38 0601802132 FUSE, 10A 1
39 011106015 HEX. HEAD BOLT ..................................... 4 .......... REPLACES 0016906015
40 0601821370 RECTIFIER ............................................... 2 .......... REPLACES 0601823240
41 0040004000 LOCK WASHER 1
41 031104080 PLAIN WASHER ........................................ 1 .......... REPLACES 0041204000
42 0330000530 EDGING 1
43 1825530400 SAFETY RELAY ........................................ 1 .......... REPLACES 0602200304
44 011106015 HEX. HEAD BOLT ..................................... 2 .......... REPLACES 0016906015
45 M12467001004 WIRE HARNESS, GENERATOR .............. 1 .......... UP TO S/N7106114
45 M1246700524 WIRE HARNESS, GENERATOR .............. 1 .......... S/N7106115~

DCA-45SSIU2 ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.

DCA-45SSIU2 ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
1 M19232000034 ENGINE .......................................... 1 .......... ISUZU B-4BG1
2 8943212191 CARTRIDGE, OIL FILTER .............. 1 .......... REPLACES 06020412113
3 X132400240 CARTRIDGE, FUEL FILTER ........... 1 .......... REPLACES 1132400791 AND 0602042511
4 M1303200103 ENGINE FOOT 1
5 M1303200203 ENGINE FOOT 1
6 0105091025 HEX. HEAD BOLT ........................... 7 ........... REPLACES 0010710025
7 004251000 LOCK WASHER 8
8 003041000 HEX. NUT 1
9 060500008 RUBBER SUSPENSION 2
10 00300120000 HEX. NUT 2
11 0040012000 LOCK WASHER 2
12 031112230 PLAIN WASHER ............................. 2 ........... REPLACES 0041212000
13 0602012740 RADIATOR, C2810050000R2 .......... 1 ........... S/N7200646 TO 7200705
13 0602012741 RADIATOR, C2810050001 ............... 1 ........... S/N7200706~
14 0602011065 CAP, RADIATOR ............................. 1 ........... C89C0115010
16 M1310500403 RADIATOR HOSE, UPPER 1
17 M1310500303 RADIATOR HOSE, LOWER 1
18 0605515147 HOSE BAND 4
19 0602046232 AIR CLEANER ................................ 1 .......... FWG065295
20 0602046368 ELEMENT. AIR CLEANER .............. 1 .......... P181052
21 0602040650 INDICATOR, AIR CLEANER ........... 1 .......... RBX002252
22 0602040595 BAND AIR CLEANER ..................... 2 .......... P007191
23 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0016908020
24 020108060 HEX. NUT ....................................... 4 .......... REPLACES 0207008000
25 M1373100203 HOSE, AIR CLEANER 1
26 060551548 HOSE BAND 2
27 0602022560 ADAPTER 1
28 M1320300304 PACKING, OIL PAN SIDE 1
29 0602022561 90O ELBOW 1
30 0602022562 UNION 1
31 0602022792 SWIVEL 1
32 0602021070 CAP 1
33 0602021572 DRAIN HOSE 1
34 M9300000103 RESERVE TANK 1
35 M9300100003 CAP, RESERVE TANK 1
36 0199100175 HOSE 1
37 M1316100404 BRACKET, RESERVE TANK 1
38 1819001902 ENGINE STOPPER ........................ 1 .......... REPLACES 0602210810
38 0601802133 FUSE, 5A 1
39 011808015 MACHINE SCREW ......................... 3 ........... REPLACES 0027106015
40 8970208220 FAN BELT ....................................... 1 .......... REPLACES 5136711320 AND 0602011403

DCA-45SSIU2 ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.

DCA-45SSIU2 ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
1 M1354300304 SLIDE LEVER 1
2 0601840190 KNOB .............................................. 1 ........... REPLACES M9320000004
3 020108060 HEX. NUT ....................................... 1 ........... REPLACES 0036003000
4 M1354200004 BRACKET 1
5 020108060 HEX. NUT ....................................... 1 ........... REPLACES 0030008000
6 06054010550 SNAP PIN 1
7 M1354300104 GOVERNOR ROD 1
8 0602180106 BALL JOINT 1
9 020108060 HEX. NUT ....................................... 2 ........... REPLACES 0030008000
10 0207006000 HEX. NUT 2
10 0041206000 PLAIN WASHER 2
11 1823100080 STARTER SWITCH ......................... 1 ........... REPLACES 0602100004
11 KEYISUZUF KEY, STARTER SWITCH 1
12 8944626110 PREHEAT LAMP ............................. 1 ........... REPLACES 9825300410 AND 0602102066
13 0602120095 TACHOMETER ................................ 1 ........... 103680
14 0602120480 PICKUP, TACHOMETER ................. 1 ........... 7154400
15 0602122093 OIL PRESSURE GAUGE ................ 1 ........... 100174
16 0602122272 UNIT, OIL PRESSURE .................... 1 ........... REPLACES 0602122271
17 M9200100004 ADAPTER ....................................... 1
18 0602123090 WATER TEMPERATURE GAUGE ... 1 ........... 100683
19 0602123260 UNIT, WATER TEMPERATURE ....... 1 ........... 0209400
20 9075720140 PACKING ........................................ 1 ........... REPLACES 9095720140 AND 0602121109
21 0602121080 CHARGING AMMETER .................. 1 ........... 100158
22 0602125090 FUEL GAUGE ................................. 1 ........... 100176
23 0602103092 ALARM LAMP ................................. 2 ........... PL-05
23 0601810245 BULB ............................................... 2 ........... E-10 T-10 DC18V
23 0601823223 RECTIFIER ..................................... 2 ........... 30D4
24 0601810141 PANEL LIGHT ................................. 1 ........... 9826800370
25 0601831330 SWITCH, PANEL LIGHT ................. 1 ........... 900001
26 020108060 HEX. NUT ....................................... 1 ........... REPLACES 0207008000
27 M1354200204 GUIDE, SLIDE LEVER ................... 1 ........... S/N7200646 TO 7200675
28 0027105015 MACHINE SCREW ......................... 2 ........... S/N7200646 TO 7200675
29 M1357200302 WIRE HARNESS. ENGINE 1

DCA-45SSIU2 OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.

DCA-45SSIU2 OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO. PART NO. ITEM QTY REMARKS
1 8111860303 TERMINAL PANEL .................................................. 1 ...... REPLACES M1230700103
2 0801831704A OUTPUT TERMINAL BOLT .................................... 5 ...... REPLACES M9220100204
3 012210020 TIE BOLT ................................................................ 5 ...... REPLACES M9220100104
4 0039310000 HEX. NUT 10
5 0040010000 LOCK WASHER 15
6 0041410000 PLAIN WASHER 20
7 0016908025 HEX. HEAD BOLT 5
8 M1236100603 TERMINAL COVER ................................................ 1 ...... S/N7200646 TO 7201195
8 M1236100613 TERMINAL COVER ................................................ 1 ...... S/N7201196~
9 M1236100704 OUTPUT WINDOW 1
10 0605010040 HINGE 2
11 0207003000 HEX. NUT ............................................................... 4 ...... REPLACES 0030003000
11 58413 PLAIN WASHER ..................................................... 4 ...... REPLACES 0041203000
12 016906020 HEX. HEAD BOLT 2
13 011106015 HEX. HEAD BOLT ................................................... 4 ...... REPLACES 0016906015
14 M1236400004 CABLE OUTLET COVER 1
15 M1236300004 SUPPORTER, CABLE OUTLET COVER 1
17 0601808803 CIRCUIT BREAKER ............................................... 2 ...... QOU 120B 19 20A
18 0601808804 CIRCUIT BREAKER ............................................... 3 ...... QOU 250B 2P 50A
19 M1260700304 BREAKER FITTING COVER 1
20 0222100150 CUSHION RUBBER 1
22 0601812597 RECEPTACLE, GF-530EM 125V 20Ax2 ................. 2 ...... REPLACES 0601812598
23 0601811034 RECEPTACLE, CS6369 250V 50A ......................... 3 ...... REPLACES 0601812538
24 0021304015 MACHINE SCREW ................................................10 ...... REPLACES 0027104015
24 0030004000 HEX.NUT ............................................................... 10 ...... REPLACES 0207004000
25 M1236100803 TERMINAL COVER 1
27 031112230 PLAIN WASHER ..................................................... 2 ...... REPLACES 0041212000
28 M9310200004 STAY RUBBER 2
29 0030012000 HEX. NUT 2
30 0207003000 HEX.NUT ................................................................ 4 ...... REPLACES 0030003000

DCA-45SSIU2 BATTERY ASSY.
BATTERY ASSY.

DCA-45SSIU2 BATTERY ASSY.
BATTERY ASSY.
1 551010280 BATTERY, 627MFD ......................... 1 .......... REPLACES 0602220187
2 M9310500014 BATTERY SHEET 1
3 M9103000304 BATTERY BAND 1
4 0602220920 BATTERY BOLT SET 2
5 0040006000 LOCK WASHER 2
6 M1346400204 BATTERY CABLE 1
7 M1346400404 BATTERY CABLE 1
8 0016910020 HEX. HEAD BOLT 1

DCA-45SSIU2 MUFFLER ASSY.
MUFFLER ASSY.

DCA-45SSIU2 MUFFLER ASSY.
MUFFLER ASSY.
1 0602300165 MUFFLER ....................................... 1 .......... 27242N
2 0016910025 HEX. HEAD BOLT 4
3 M1333001303 EXHAUST PIPE 1
4 1141450690 GASKET ......................................... 1 .......... REPLACES 0602320004
5 M1333200114 GASKET 1
6 9098400850 HEX. NUT ....................................... 3 .......... REPLACES 0602323001
6 0040010000 LOCK WASHER 3
7 0016908035 HEX. HEAD BOLT 4
8 M1330400304 COVER 1
9 M1333300004 BRACKET 1
10 0016906015 HEX. HEAD BOLT 4
11 0602326090 U BOLT SET 1

DCA-45SSIU2 FUEL TANK ASSY.
FUEL TANK ASSY.

DCA-45SSIU2 FUEL TANK ASSY.
FUEL TANK ASSY.
1 M1363000302 FUEL TANK 1
2 0605505070 CAP, FUEL TANK 1
3 M1363200104 TANK BAND 2
4 M9310500104 SUPPORTER SHEET 4
6 0207308000 HEX. NUT 2
7 0222100600 RUBBER SHEET 2
8 M9200000003 DRAIN JOINT 1
9 M9200200004 DRAIN BOLT 1
10 0150000018 O RING 1
12 M1363400104 DRAIN HOSE 1
13 0605515198 HOSE BAND 2
14 0602042420 FUEL FILTER 1
15 0602220911 CLAMP 1
16 0191301200 SUCTION HOSE 1
17 0191300300 SUCTION HOSE 1
18 0191302000 RETURN HOSE 1
19 0605515109 HOSE BAND 6

DCA-45SSIU2 ENCLOSURE ASSY.
ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE 5 -BLACK
2-WHITE 6 -CATERPILLAR YELLOW
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.

DCA-45SSIU2 ENCLOSURE ASSY.
ENCLOSURE ASSY.
1 M1413000402 BASE 1
2 M1413400004 UNDER COVER 1
4 M1423000902 FRONT FRAME .............................. 1 .......... S/N7200646 TO 7200740
4 M1423000912 FRONT FRAME .............................. 1 .......... S/N7200741~
4 M1493102703 ACOUSTIC SHEET 1
6 M1423200604 COVER, FRONT FRAME 1
7 011008020 HEX. HEAD BOLT ......................... 12 .......... REPLACES 0016908020
8 M1423200703 INNER COVER. FRONT FRAME .... 1 .......... S/N7200646 TO 7200740
8 M1423200713 INNER COVER, FRONT FRAME .... 1 .......... S/N7200741~
10 M1433000403 CENTER FRAME 1
11 M1433000003 CENTER FRAME 1
12 0010114030 HEX. HEAD BOLT 8
12 030214350 LOCK WASHER .............................. 8 .......... REPLACES 0040014000
12 031114260 PLAIN WASHER ............................. 8 .......... REPLACES 0041214000
13 00400120000 SPRING WASHER 10
13 031112230 PLAIN WASHER ........................... 10 .......... REPLACES 0041212000
14 M1443000702 REAR FRAME 1
15 011008020 HEX. HEAD BOLT ............................4 .......... REPLACES 0016908020
16 M1443300613 REAR COVER 1
17 M1443300303 DUCT, REAR COVER 2
18 0207006000 HEX. NUT 12
20 M1443200803 REAR DOOR 1
21 M1443600204 WINDOW PLATE 1
22 020106050 HEX. NUT ....................................... 8 .......... REPLACES 0207306000
22 00412060000 PLAIN WASHER 8
23 B9114000002 DOOR HANDLE ASSY. ................... 1 .......... REPLACES M9113000002
24 0027106016 MACHINE SCREW ......................... 4 .......... REPLACES 0021806015
24 020106050 HEX. NUT ....................................... 4 .......... REPLACES 0030006000
25 M9110100204 HINGE 2
26 M9116100004 WASHER 2
28 0845031504 BLIND PLUG ................................... 2 .......... REPLACES M9310000004
29 M1463000702 ROOF PANEL 1
31 1625165103 BONNET CAP ................................. 1 .......... REPLACES M9310000103

DCA-45SSIU2 ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE 5 -BLACK
2-WHITE 6 -CATERPILLAR YELLOW
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.

DCA-45SSIU2 ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
32 1625165204 CHAIN ASSY. ................................. 1 ........... REPLACES M1483600204
33 M1453200002 SPLASHER PANEL ........................ 1 ........... S/N7200646 TO 7201195
33 M1453200012 SPLASHER PANEL ........................ 1 ........... S/N7201196~
36 M1453001503 SIDE DOOR 1
37 M1453002003 SIDE DOOR 1
38 M1453001303 SIDE DOOR 1
39 M1453001203 SIDE DOOR 1
40 M1453300603 DUCT 1
41 0207006000 HEX. NUT 5
42 B9114000002 DOOR HANDLE ASSY. ................... 3 ........... REPLACES M9113000002
43 0027106016 MACHINE SCREW ....................... 12 ........... REPLACES 0021806015
43 020106050 HEX. NUT ..................................... 12 ........... REPLACES 0030006000
44 M9110100204 HINGE 4
45 M9110100304 HINGE 4
46 M9116100004 WASHER 8
48 0601850097 DOOR STOPPER 8
50 0845031504 BLIND PLUG ................................... 8 ........... REPLACES M9310000004
51 0600500090 EMBLEM 1
54 0016910020 HEX. HEAD BOLT 1

DCA-45SSIU2 RUBBER SEAL ASSY.
RUBBER SEAL ASSY.

DCA-45SSIU2 RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
1 0228901400 RUBBER SEAL 3
2 0229200695 RUBBER SEAL 1
3 0228900620 RUBBER SEAL 1
4 0228900940 RUBBER SEAL 1
5 M1490300104 RUBBER SEAL 1
6 0228800515 RUBBER SEAL 1
7 0228900420 RUBBER SEAL 1
8 0228900910 RUBBER SEAL 3
9 0229200900 RUBBER SEAL 1
10 0229200840 RUBBER SEAL 1
11 0228800780 RUBBER SEAL 2
12 0228800470 RUBBER SEAL 1
13 0228800510 RUBBER SEAL 1
14 0228100545 RUBBER SEAL 1
15 0228100370 RUBBER SEAL 1
16 0228100165 RUBBER SEAL 1
17 0228100340 RUBBER SEAL 1
18 0228100170 RUBBER SEAL 1
19 0228100200 RUBBER SEAL 1

DCA-45SSIU2 NAMEPLATE AND DECALS
NAMEPLATE AND DECALS

DCA-45SSIU2 NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
1 M1550000204 DECAL, NOTE ....................................................... 1 ...... M15000020
2 M1550001003 DECAL, GENERATOR CONTROL ......................... 1 ...... M15000100
3 M1550000603 DECAL, ENGINE OPERATING .............................. 1 ...... M15000060
4 M1550000703 DECAL, AUXILIARY OUTPUT ...............................1 ...... M15000070
5 M1550000804 DECAL, NOTE ....................................................... 1 ...... M15000080
6 M9500000004 DECAL, OIL DRAIN PLUG .....................................1 ...... M9000000
7 M9500100004 DECAL, WATER .....................................................1 ...... M90010000
8 M9500300004 DECAL, - ................................................................1 ...... M90030000
9 M9500300104 DECAL, + ............................................................... 1 ...... M90030010
10 M9500500004 DECAL, DIESEL FUEL .......................................... 1 ...... M90050000
11 M9500500104 DECAL, FUEL DRAIN PLUG ................................. 1 ...... M90050010
12 M9503000004 DECAL, WARNING ................................................. 2 ...... M90300000
13 M9503000103 DECAL, WATER, OIL CHECK ................................1 ...... M90310000
14 M9503100004 DECAL, WARNING ................................................. 1 ...... M90320000
15 M9503200004 DECAL, WARNING ................................................. 1 ...... M90320000
16 M9510100004 DECAL, CAUTION ................................................. 1 ...... M91010000
17 M9510200002 DECAL, MQ ...........................................................1 ...... M91020000
18 M9520000004 DECAL, GROUND ..................................................1 ...... M92000000
19 M9520000104 DECAL, AMMETER CHANGE-OVER SWITCH ..... 1 ...... M92000010
20 M9520000204 DECAL, VOLTMETER CHANGE-OVER SWITCH .. 1 ...... M92000020
21 M9520100004 DECAL, WARNING ................................................. 2 ...... M92010000
22 M9520100204 DECAL, CAUTION ................................................. 1 ...... M92010020A
23 M9520100304 DECAL, SAFETY INSTRUCTIONS ....................... 1 ...... M92010030
24 M9520100404 DECAL, DANGER ..................................................1 ...... M92010040
25 M9520100503 DECAL, WARNING ................................................. 1 ...... M92010050
26 M9520200003 DECAL, CONNECTION OF OUTPUT CABLE ....... 1 ...... M92020000
27 M9520200104 DECAL, OVER CURRENT RELAY ......................... 1 ...... M92020010
28 M1560100603 STRIPE, WHISPERWATT 1
29 M1560100703 STRIPE, MQ POWER 2
30 M1560101204 STRIPE 1
31 M1560101104 STRIPE 2
32 M1560100904 STRIPE, 45 2
33 M1560100804 STRIPE 1
34 M1560101004 STRIPE 1
35 M1940011015Q DECAL, FUELING PROCEDURE 1

ISUZU 4BG1 CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.

ISUZU 4BG1 CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
NO PART NO PART NAME QTY. REMARKS
1 8971334460 COVER 1
4 8941332075 CAP 1 EA1013
5 8941236231 GASKET, OIL FILLER 1
27 9111790300 GASKET, HEAD COVER 3
68 9111791050 WASHER 3
69 8943109120 GASKET, HEAD TO COVER ........... 1 .......... REPLACES 8944625590
75 9111750120 NUT 3

ISUZU 4BG1 CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.

ISUZU 4BG1 CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
1 8971418211 CYLINDER HEAD ASSY. .................. 1 ........ INCLUDES ITEM W/
2 8944189200 GASKET, HEAD 1
*
3 8943674380 BOLT ................................................. 4 ........ M12X 115
3 8943674370 BOLT ................................................. 4 ........ M12X102
4 5117510010 GUIDE, VALVE 8
*
5A
5B
* 8970376860 VALVE INSERT SEAT, INLET 4
6
* 5117110280
9096600340
VALVE, INSERT SEAT, EXHAUST 4
PLUG PLATE 4
*
7A
7B
* 1096000051
5112190150
SEALING CYL. HEAD CUP .............. 1 ........ OD=45
7C
*
7D
* 1096000160 SEALING CYL. HEAD CUP .............. 4 ........ OD-25
7E
* 9111291280
1096000160
7F
* 5096000130 SEALING CYL. HEAD CUP .............. 4 ........ OD=12.3
8
* 9111296010 CUP, SEALING WATER JACKET 4
9 9041108250 INLET MANIFOLD STUD 2
10 9825139289 GLOW PLUG 4
11 5197320021 GLOW PLUG CONNECTOR 1
12 9117778050 REAR ENG. HANGER 1
13 0500410200 HANGER BOLT 4
14 9041108750 STUD, EX. MANIFOLD ...................... 3 ........ M8X75 L=87
14 9098301770 STUD, EX. MANIFOLD ...................... 1 ........ M8X85 L=97
53 1093000180 INJ. NOZZLE STUD 8
54 5093000650 ROCKER ARM STUD 3
168 5117770640 FRONT ENG. HANGER 1

ISUZU 4BG1 CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.

ISUZU 4BG1 CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 8971239542 CYLINDER BLOCK ASSY. ..................................... 1 .......... INCLUDES ITEM W/
2 5878133000 LINER SET ............................................................. 1 .......... GRADE 1
*
2 4878133010 LINER SET ............................................................. 1 .......... GRADE 2
2 4878133020 LINER SET ............................................................. 1 .......... GRADE 3
2 5878133030 LINER SET ............................................................. 1 .......... GRADE 4
4 1112612480 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=1 ID GRD=AX
*
4 1112612490 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=1 ID GRD=CX
*
*
*
*
*
*
*
8 1090004691 BOLT 2
*
13 8941480790 DOWEL 2
15A 9992055170 OIL GALLERY PLUG ............................................. 1 .......... PT 3/8
15B 5096050180 OIL GALLERY PLUG ............................................. 7 .......... PT 1/8 (SQUARE HEAD)
23 5112190140 CUP, SEALING 1
*
25A 9116110480 CAMSHAFT METAL 1
*
25B 9116130350 CAMSHAFT METAL 2
28
* 8941745290 OIL PORT COVER 1
29 8943706630 OIL PORT COVER GASKET 1
34 8970233390 OIL RELIEF VALVE 1
35 5096230350 OIL RELIEF GASKET 1
37 1096050681 OIL GALLERY PLUG 2
38 1097400780 TIMING GEAR CASE PIN 1
40 8943444620 SEALING CUP 1
45 9827200690 OIL PRESSURE SWITCH 1
56 1133420742 PISTON COOLING OIL JET 4
70 1096000520 SEALING CUP 2
*
71 8943673681 GASKET 2
72 8970285250 TAPPET CHAMBER COVER 1
73 9112916051 TAPPET CHAMBER ASSY. 1
74 8943675301 BOLT
80 1096000121 TAPPET CHAMBER SEALING CUP 2
*
83 9081510180 FLYWHEEL HOUSING PIN 2
130 5112570011 BRIDGE CAP DOWEL 1
*
132 1131610120 OIL CHECK VALVE 4
136 5112240040 OIL PUMP SHAFT DRIVE BUSHING 1
137 5096800110 WATER DRAIN COCK 1
140 5096600330 INJ. PUMP NIPPLE 1
141 0500408180 BOLT, COVER 2
162 1093660330 CYL. BLOCK WATER DRAIN HOSE ..................... 1 .......... REPLACES 9099135050
179 9095720080 GASKET 4
200 9992023140 OIL GALLERY PLUG 1
218 9095720140 GASKET PLUG 1
236 1093000790 ENGINE FOOT STUD 1
267 5097070041 DRAIN HOSE CLIP 1
301 5111290030 SEALING LEVEL GAUGE CUP 1

ISUZU 4BG1 OIL PAN AND LEVEL GAUGE ASSY.
OIL PAN AND LEVEL GAUGE ASSY.

ISUZU 4BG1 OIL PAN AND LEVEL GAUGE ASSY.
OIL PAN AND LEVEL GAUGE ASSY.
1 8941340361 OIL PAN ASSEMBLY .................................. 1 ............... INCLUDES ITEM W/
2 5117601500 OIL LEVEL GAUGE 1
*
3 1096230570 DRAIN PLUG GASKET 1
4
* 9096620120 OIL DRAIN PLUG 1
*
16 8943706660 OIL PAN GASKET 1
23 0500408180 BOLT 24
119A 9992023160 OIL HEATER BLIND PLUG 2
119B
* 9992023240 OIL HEATER BLIND PLUG 1
120A
* 9095714160 GASKET 2
120B
* 9095714240 GASKET 1
277
* 1117500120 OIL FILLER CAP 1

ISUZU 4BG1 CAMSHAFT AND VALVE ASSY.
CAMSHAFT AND VALVE ASSY.

ISUZU 4BG1 CAMSHAFT AND VALVE ASSY.
CAMSHAFT AND VALVE ASSY.

1 8944094120 CAMSHAFT 1
4 1125510501 INLET VALVE 4
5 1125520251 EXHAUST VALVE 4
7 5090002360 BOLT 1
9 1125220161 CAMSHAFT GEAR 1
10 9116810150 THRUST PLATE 1
11 0500408250 BOLT 2
12 9080107200 KEY 1
45 9098518503 WASHER 1
53 8941295510 ROCKER ARM SHAFT 1
55 9126260050 ROCKER ARM PLUG 2
58 5126280120 ROCKER ARM BRACKET 1
59 5096230600 ROCKER SHAFT GASKET 1
65 5125650060 SPLIT COLLAR 16
69 5125610090 OUTER VALVE SPRING 8
71A 8941145790 SPRING SEAT, UPPER 8
71B 1125630351 SPRING SEAT, LOWER 8
72 1125690150 VALVE GUIDE SEAT 8
76 9098514300 WASHER 3
78 5126110310 ROCKER ARM 8
81 9126160420 ADJ. SCREW 8
83 9091115080 ADJ. SCREW NUT 8
84 9126281050 ROCKER SHAFT BRACKET 4
85 1090005670 BOLT 6
86 9098514300 WASHER 6
88 1125750360 PUSH ROD 8
89 5125710032 VALVE TAPPET 8
93 1094001160 NUT 3
95 1095803350 ROCKER SHAFT SPRING 3
101 5090300381 BOLT 2
107 9125310300 IDLE GEAR SHAFT 1
111 5125350011 THRUST COLLAR 1
112 8941339372 IDLER GEAR 1
196 9091800190 SNAP RING 1

ISUZU 4BG1 CRANKSHAFT, PISTON AND FLYWHEEL ASSY.
CRANKSHAFT, PISTON AND FLYWHEEL ASSY.

ISUZU 4BG1 CRANKSHAFT, PISTON AND FLYWHEEL ASSY.
CRANKSHAFT, PISTON AND FLYWHEEL ASSY.
1 8943398950 CRANKSHAFT 1
7 8970716610 CRANKSHAFT, STD KIT .......... 1 ........... INCLUDES ITEM W/# REPLACES 8941170322
12 8970461810 FLYWHEEL 1
28 8971379100 CRANKSHAFT GEAR 1
32 9081612200 FLYWHEEL PIN 1
33 5123190032 CRANKSHAFT RING 1
35 9123336070 GEAR RING 1
37 9000901570 PILOT BEARING 1
38 5123360030 WASHER 1
40 5123340060 BOLT 6
42# 8970713580 WASHER .................................. 2 ........... REPLACES 8941145652
44 5123780020 NUT 1
48 8941075970 KEY 2
56 8941004540 CRK DAMPER PULLEY 1
59 5095030240 WASHER 1
63 8971766500 PISTON, STD. .......................... 4 ........... GRADE=AX
63 8971766510 PISTON, STD. .......................... 4 ........... GRADE=CX
68 8971238330 RING SET 4
73 9122716080 CONN. ROD METAL SET 4
83 912211604 PISTON PIN 4
84 1122301041 CONNECTING ROD ASSY. ..... 4 ........... INCLUDES ITEMS W/$
85$ 1122510270 BUSHING 4
86$ 1122350271 BOLT 8
126 8941075751 SNAP PIN RING 8

ISUZU 4BG1 TIMING GEAR AND FLYWHEEL HOUSING ASSY.
TIMING GEAR AND FLYWHEEL HOUSING ASSY.

ISUZU 4BG1 TIMING GEAR AND FLYWHEEL HOUSING ASSY.
TIMING GEAR AND FLYWHEEL HOUSING ASSY.
1 8944509752 TIMING GEAR CASE 1
2 8943213304 FLYWHEEL HOUSING 1
36 0500408200 BOLT .............................................. 4 ........... M8X20 W/ LOCK WASHER
39 8943706710 GASKET 1
42 9112290581 DOWEL 1
49 8943706720 GASKET 1
54 8971298300 GEAR CASE COVER 1
57 5113210090 TIMING CHECK COVER 2
58 0500406140 BOLT 4
60 0500408250 BOLT .............................................. 8 ........... MX45 W/ LOCK WASHER
60 0500408800 BOLT .............................................. 1 ........... M8X80W/ LOCK WASHER
60 5090000841 BOLT .............................................. 4 ........... M8X55 W/LOCK WASHER
60 5090300381 BOLT .............................................. 3 ........... M10X55
65 8970276011 GASKET 2
86 8944533001 TACHO DRIVE ELBOW 1
93 1096234650 ELBOW GASKET 1
103 1096254380 OIL SEAL, FRONT 1
175 1096253630 OIL SEAL, REAR 1
211 0500408250 BOLT 7
242 9095714160 PLUG GASKET 1
252 0500408200 BOLT 2
290 8943218380 PLUG 1
382 9992023160 HOUSING PLUG 1

ISUZU 4BG1 ENGINE MOUNTING ASSY.
ENGINE MOUNTING ASSY
ISUZU 4BG1 ENGINE MOUNTING ASSY.
ENGINE MOUNTING ASSY.

2C 9117712470 ENGINE FOOT, RIGHT 1
2D 9117712480 ENGINE FOOT, LEFT 1
20 8943134650 BOLT 7
125 9091105100 NUT 1
251 9091505100 LOCK WASHER 1
ISUZU 4BG1 INLET MANIFOLD ASSY.
INLET MANIFOLD ASSY.
ISUZU 4BG1 INLET MANIFOLD ASSY.
INLET MANIFOLD ASSY.

1 8971333280 INLET MANIFOLD 1
7 8970241220 GASKET 1
20 0911501080 NUT 2
52 8943216751 INLET PIPE 1
60 8943706760 GASKET 1
60 8970225710 GASKET 1
138 5141111970 INLET PIPE 1
144 0500408250 BOLT 6
ISUZU 4BG1 EXHAUST MANIFOLD ASSY.
EXHAUST MANIFOLD ASSY.
ISUZU 4BG1 EXHAUST MANIFOLD ASSY.
EXHAUST MANIFOLD ASSY.
1 5141410360 EXHAUST MANIFOLD 1
2 8944046100 GASKET 2
15 8943185540 BOLT ................................................... 1 ............. M8X63 W/PLAIN WASHER
15 8943185550 BOLT ................................................... 3 ............. M8X75 W/ PLAIN WASHER
16 9044110300 EXHAUST PIPE STUD 3
88 8941704860 NUT 4
ISUZU 4BG1 VENTILATION ASSY.
VENTILATION ASSY.
ISUZU 4BG1 VENTILATION ASSY.
VENTILATION ASSY.
141 894110110 DIAPHRAGM ASSY. 1
142 1143620020 PCV COVER 1
143 9934905100 SCREW 6
ISUZU 4BG1 WATER PUMP AND CORROSION RESISTOR ASSY.
WATER PUMP AND CORROSION RESISTOR ASSY.
ISUZU 4BG1 WATER PUMP AND CORROSION RESISTOR ASSY.
WATER PUMP AND CORROSION RESISTOR ASSY.
2 8971250510 WATER PUMP ASSY. .......... 1 ..................... INCLUDES ITEMS W/
3# 8943706610 GASKET 1
*
4 8943809470 REPAIR KIT .......................... 1 ..................... INCLUDES ITEMS W/#
7
* 8944161302 WATER PUMP PULLEY 1
9 # 9091801470 RING 1
*
18 # 5136210110 WATER PUMP IMPELLER 1
*
19 # 5136130070 GASKET 1
*
20 # 5136120100 COVER 1
*
25 # 5136420530 CENTER 1
*
26 # 5136390020 DUST COVER 1
*
27 # 5098000520 BEARING 2
*
28 # 5095030990 WASHER 1
*
29 # 8943777860 SHAFT 1
*
30 # 9099521030 SNAP RING 1
*
32 # 5136200061 SEAL 1
*
34 # 9090908200 SCREW 3
36
* 0500410400 BOLT .................................... 1 ..................... M10X40 W/LOCK WASHER
36 5090300101 BOLT .................................... 2 ..................... M10X75 W/LOCK WASHER
36 0500410500 BOLT .................................... 1 ..................... M10X50 W/ LOCK WASHER
57 5096050050 HEATER PLUG 1
66 # 5096250780 SECONDARY SEAL 1
*
67 # 5136390070 SLINGER 1
*
ISUZU 4BG1 THERMOSTAT AND HOUSING ASSY.
THERMOSTAT AND HOUSING ASSY.
ISUZU 4BG1 THERMOSTAT AND HOUSING ASSY.
THERMOSTAT AND HOUSING ASSY.
1 5137700301 THERMOSTAT 1
2 8944033142 HOUSING 1
14 9096610050 SWITCH 1
27 9095713160 GASKET .................................... 1 ................ REPLACES 9095714160
28 5096050050 HEATER PLUG 1
44 0501410250 BOLT ......................................... 4 ................ M10X25 W/LOCK AND PLAIN WASHER
49 8944017531 WATER OUTLET PIPE 1
50 0500408250 BOLT 3
58 5096050050 WATER OUTLET PLUG 1
64 8941760310 GASKET 1
66 8943706730 GASKET 1
ISUZU 4BG1 ENGINE WATER PIPING ASSY.
ENGINE WATER PIPING ASSY.
ISUZU 4BG1 ENGINE WATER PIPING ASSY.
ENGINE WATER PIPING ASSY.
2 8941324900 HOSE 1
148 9099153151 CLIP 2
ISUZU 4BG1 FAN AND FAN BELT ASSY.
FAN AND FAN BELT ASSY.
ISUZU 4BG1 FAN AND FAN BELT ASSY.
FAN AND FAN BELT ASSY.
1 8970699020 COOLING FAN 1
16 9098516490 WASHER 4
24 8942059861 BOLT ...................................... 4 ................... M8X65
36 8970208220 BELT....................................... 1 ................... REPLACES 5136711320
38 1136420250 SPACER 1
77 9091647080 WASHER 1
80 5136740320 ADJUSTING PLATE 1
86A 0500408220 BOLT 1
86B 0501410300 BOLT 1
ISUZU 4BG1 FUEL INJECTION ASSY.
FUEL INJECTION ASSY.
ISUZU 4BG1 FUEL INJECTION ASSY.
FUEL INJECTION ASSY.
1 8971612100 INJECTION PUMP ASSY. ......... 1 ................ INCLUDES ITEM W/
*
15 8971230631 COUPLING ASSY. 1
*
16 8970314671 INJ. PIPE, NO. 1 1
17 8970314681 INJ. PIPE, NO. 2 1
18 8970314691 INJ. PIPE, NO. 3 1
19 8970314701 INJ. PIPE, NO. 4 1
31 1153002912 NOZZLE ASSY. 4
32# 8970161471 NOZZLE HOLDER ASSY. ......... 4 ................ INCL. ITEMS W/%
33# 5153110270 NOZZLE ASSY. ......................... 4 ................ INCL. ITEMS W/#
34%# 1153390090 BOLT 4
35%# 1153320170 NUT 4
36%# 1153390100 GASKET 8
37%# 5153320060 NUT 4
38%# 5153390600 GASKET 4
39%# 8941695030 SCREW 4
41%# 8943203080 CONNECTOR 4
42%# 5513390030 GASKET 4
45%# 8941695020 PUSH ROD 4
46%# 9153470030 NOZZLE PIN 8
54 9153390510 COVER 4
62 0911501080 NUT 8
63 5154110420 LEAK OFF PIPE ....................... 1 ................ REPLACES 8970209371
65 9095720140 GASKET 4
66 5153150030 GASKET 4
75 9091605100 WASHER 1
80 5197510150 BRACKET 1
82 9091505100 WASHER 1
84 9091105100 NUT 1
87 0500410250 BOLT 2
93 9095714080 GASKET 2
113 5154190131 CLIP 3
133 5154112231 NOZZLE PIPE 1
133 8970209350 NOZZLE PIPE 1
134 1096750371 BOLT 1
138%# 5153430050 SPRING 4
ISUZU 4BG1 FUEL FILTER AND BRACKET ASSY.
FUEL FILTER AND BRACKET ASSY.
ISUZU 4BG1 FUEL FILTER AND BRACKET ASSY.
FUEL FILTER AND BRACKET ASSY.
1 1132007011 FUEL FILTER ASSY. ................. 1 ................ REPLACES 8944537371 AND 8941517451
* ...................................................................... INCLUDES ITEMS W/
20 5154112231 EYE JOINT 1
*
21 1132120870 COVER ...................................... 1 ................ REPLACES 5132120751
29
* 1132600470 OVERFLOW VALVE .................. 1 ................ REPLACES 9132600562
30
* 1096300850 GASKET .................................... 2 ................ REPLACES 9095720140
40
* 5197550010 BRACKET 1
45 0501410350 BOLT 2
47 0501408250 BOLT 2
54 1094680021 NUT 1
58 X132400240 ELEMENT ................................. 1 ................ REPLACES 8944147963, 1132400791
69
* 9099063251 BOLT 2
88 0500410200 BOLT 2
ISUZU 4BG1 FUEL PUMP AND PIPE ASSY.
FUEL PUMP AND PIPE ASSY.
ISUZU 4BG1 FUEL PUMP AND PIPE ASSY.
FUEL PUMP AND PIPE ASSY.
107 5154114570 PIPE .......................................... 1 ................ REPLACES 8970209330
119 9154127311 PIPE .......................................... 1 ................ REPLACES 8970209340
150 9095720140 GASKET 2
158A 5154190040 CLIP 1
158B 5154190051 CLIP 1
159 0501406160 BOLT 1
ISUZU 4BG1 OIL COOLER AND OIL FILTER ASSY.
OIL COOLER AND OIL FILTER ASSY.
ISUZU 4BG1 OIL COOLER AND OIL FILTER ASSY.
OIL COOLER AND OIL FILTER ASSY.
2 A$ 8943212191 ELEMENT, OIL FILTER 1
89 5112890090 BOLT, ELEMENT TO CASE 1
90 1217290430 GASKET, BOLT, OIL COOLER 1
109 0500408250 BOLT, M8X25 ............................................ 11 ........... W/LOCK WASHER
109 0500408450 BOLT, M8 X45 ............................................. 8 ........... W/LOCK WASHER
109 0500408200 BOLT, M8X20 .............................................. 2 ........... W/LOCK WASHER
109 8942058961 BOLT, M8X65 1
110 8944496450 BODY; CASE, OIL COOLER 1
111 8970320250 CORE; OIL COOLER 1
112 A 8971281500 PLUG; OIL COOLER CASE 1
112 B 5112880020 PLUG; OIL COOLER CASE 1
113 A 8944706680 GASKET; PLUG; OIL COOLER CASE 1
113 B 9095716200 GASKET; PLUG; OIL COOLER CASE 1
281 B$ 8970261351 COVER, OIL FILTER ................................... 1 ........... INCLUDES ITEMS W/
288 $ 9132630100 PLUG; OIL DRAIN 1
*
*
290 $ 9099211930 GASKET; PLUG OIL DRAIN 1
321
* 8943706700 GASKET; OIL FILTER TO C/BL 1
329 A 5090000071 BOLT, M10X135 4
331 9091605100 WASHER 4
392 9091505100 LOCK WASHER 4
444 5112820110 GASKET;ELEMENT TO BODY 1
469 8970196530 GASKET; OIL COOLER TO C/BL 1
484 9099168190 CLIP 2
496 B 8970209271 FILTER ASSY. ............................................. 1 ........... INCLUDES ITEMS W/$
526 5112800111 COVER; WATER DUCT 1
ISUZU 4BG1 OIL PUMP AND OIL STRAINER ASSY.
OIL PUMP AND OIL STRAINER ASSY.
ISUZU 4BG1 OIL PUMP AND OIL STRAINER ASSY.
OIL PUMP AND OIL STRAINER ASSY.
1 5131001373 OIL PUMP ASSY. ...................... 1 ................ INCLUDES ITEMS W/$
2$ 5131650040 SPRING SEAT 1
3$ 9081040300 PIN 1
5$ 5095800980 COIL SPRING 1
8$ 5131250020 GEAR 1
19$ 5878102022 GEAR SET ................................ 1 ................ INCLUDES ITEMS W/#
29 0500410250 BOLT 2
32$# 1131280180 PINION 1
34$# 5131210140 SHAFT 1
35$ 5131130351 COVER 1
38A$ 5131410171 CASE 1
38B$ 5131410180 CASE 1
40$# 1131230160 COUPLING 1
41$ 5098430030 VALVE BALL 1
42$ 5131190060 STRAINER 1
43$ 0108058000 BOLT 4
67$ 9091505080 WASHER 4
86$ 1131190010 SPACER 1
ISUZU 4BG1 OIL AND VACUUM PIPING ASSY.
OIL AND VACUUM PIPING ASSY.
ISUZU 4BG1 OIL AND VACUUM PIPING ASSY.
OIL AND VACUUM PIPING ASSY.
1 8971242340 PIPE 1
26 8941753012 PIPE 1
28 9099211880 GASKET 2
37 5133112561 PIPE 1
40 0501408450 BOLT ...................................... 4 ................... M8X45 W/LOCK AND PLAIN WASHER
40 0500408350 BOLT ...................................... 2 ................... M8X35 W/LOCK WASHER
40 0500408320 BOLT ...................................... 2 ................... M8X32 W/LOCK WASHER
47 1096234620 GASKET 2
116 9095720100 GASKET 2
142 9098440220 NUT 1
279 8941625680 CLIP 2
343 1093600430 HOSE 1
434 0911501080 NUT 1
448 8941405812 FILLER 1
ISUZU 4BG1 ELECTRICAL CONTROL ASSY.
ELECTRICAL CONTROL ASSY.
ISUZU 4BG1 ELECTRICAL CONTROL ASSY.
ELECTRICAL CONTROL ASSY.
1 1811001911 STARTER ASSY. ....................... 1 ................ 24V 4.5KW
2 8971433290 GENERATOR ASSY. ................. 1 ................ 24V 30A
4 0500512280 BOLT ......................................... 1 ................ M12X28
4 0287812350 BOLT ......................................... 2 ................ M12X35
19 5197110620 BRACKET 1
26 050041000 BOLT ......................................... 1 ................ M10X100
26 0500410450 BOLT ......................................... 1 ................ M10X45 W/LOCK WASHER
26 5090300101 BOLT ......................................... 1 ................ M10X75 W/LOCK WASHER
38 9825300460 RESISTOR
89 8970299880 SWITCH 1
252 8943717120 COVER 1
286 0911502080 NUT 1
288 9091606080 PLAIN WASHER 1
ISUZU 4BG1 BATTERY RELAY ASSY.
BATTERY RELAY ASSY.
ISUZU 4BG1 BATTERY RELAY ASSY.
BATTERY RELAY ASSY.
68 1823200010 BATTERY RELAY 1
ISUZU 4BG1 STARTER COMP. ASSY.
STARTER COMP. ASSY.
ISUZU 4BG1 STARTER COMP. ASSY.
STARTER COMP. ASSY.
1 1811293940 SEAL KIT ........................... 1 ................. INCLUDES ITEMS W/ SHOWN IN PICTURE
2 1811230250
*
CASE ................................. 1 ................. INCLUDES ITEMS W/#
3# 1811293970 METAL 1
4 5811291420 COVER 1
5 5811291440 CLIP 1
6 5811291450 STOPPER 1
8 1811130260 BRACKET 1
9% 1811293860 BEARING 1
10 1811230240 SHAFT ............................... 1 ................. INCL. ITEM W%
11A 5811291580 WASHER 1
11B 5811291590 WASHER 2
11C 5811291600 WASHER 1
12 1811130730 BRACKET 1
15 1811160440 WIRE 1
16 1811210370 ARMATURE ....................... 1 ................. INCL.UDES ITEMS W/$
17A$ 5811291550 BEARING 1
17B$ 1811291960 BEARING 1
18$ 5811291560 WASHER 1
19 1811293960 COIL 1
20@ 1811160420 BRUSH 1
21@ 1811170140 SPRING 1
22@ 1811180360 HOLDER 1
23@ 1811150620 COVER 1
27A 1811293870 BOLT 3
27B 5811292140 BOLT 2
28 1811270310 LEVER 1
29 1811291850 PIN 1
30 5811291470 PLATE 1
31 5811510360 SWITCH 1
50@ 1811160430 BRUSH 1
54 5811220160 CLUTCH 1
57 1811150610 COVER ASSY. ................... 1 ................. INCLUDES ITEMS W/@
59 5811291500 TERMINAL 1
61 5811291480 CONTACT 1
62 9821161400 BUSHING 1
63 5811180190 HOLDER 1
64 9821161420 WASHER 1
65 5811291490 RING 2
77 1811291140 WASHER 2
78 1811293840 TERMINAL 1
80 1811291840 NUT 1
86 1825530370 RELAY 1
ISUZU 4BG1 INJECTION PUMP COMP. ASSY. (CONT.)
INJECTION PUMP COMP. ASSY. (CONT.)
1 5156110590 HOUSING 1
6 5156440170 HOLDER 4
7 1096230520 GASKET 4
8 5156290450 STOPPER 4
9 5156430010 SPRING 4
10 1156490010 GASKET 4
14 5156410030 VALVE 4
19 8943771540 PLUNGER 4
33 1096230130 GASKET 1
46 1156192430 COVER 1
48 5156191560 GASKET 1
49 9812250470 RING 1
50 5156210190 CAMSHAFT 1
51 5156190490 KEY 1
58 9812250580 SLEEVE 4
62 9812350150 SEAT 4
63 5156430090 SPRING 4
64 9812350210 SEAT 4
68 9812212230 TAPPET .......................................... 4 .................. INCL. ITEMS W/
69 5156190410 GUIDE 4
*
70 9812222200 PIN 4
*
71 1156290010 BUSHING 4
*
72 1156220030 ROLLER 4
*
73 8943865960 GASKET 1
74 8941711090 COVER 1
75 1156190030 SCREW 2
79 9812151150 STUD 3
80 8941711100 NUT 3
82 5156191360 PLUG 4
88 9019006140 BOLT 4
89 9095720100 GASKET 2
102 1132600011 VALVE 1
103 1157590010 GASKET 1
105 9000906770 BEARING ....................................... 1 .................. NSK
105 5098000380 BEARING ....................................... 1 .................. NTN
107 5156290150 SHIM ............................................... 1 .................. T=0.10
107 5156290160 SHIM ............................................... 1 .................. T=0.12
107 5156290170 SHIM ............................................... 1 .................. T=0.14
107 5156290180 SHIM ............................................... 1 .................. T=0.16
107 5156290190 SHIM ............................................... 1 .................. T=0.18
107 5156290200 SHIM ............................................... 1 .................. T=0.50
107 5156290380 SHIM ............................................... 1 .................. T=1.00
107 9812250330 SHIM ............................................... 1 .................. T=0.30
107 5156190390 SHIM ............................................... 1 .................. T=0.70
107 5156290900 SHIM ............................................... 1 .................. T=1.40
107 1156390880 SHIM ............................................... 1 .................. T=2.40
114 9000906770 BEARING ....................................... 1 .................. NSK
114 5098000380 BEARING ....................................... 1 .................. NTN
117 1157590010 GASKET 2
118 1156190820 BOLT 1
126 9812350170 ADAPTER 1
127 5156190440 ADAPTER 1
130 9019006140 SCREW 4
148 9812151440 GASKET 2
155 1156190240 BOLT 1
157 8941445880 GASKET 1
159 9812250470 RING 1
162 5156290150 SHIM ............................................... 1 .................. T=0.10
162 5156290160 SHIM ............................................... 1 .................. T=0.12
162 5156290170 SHIM ............................................... 1 .................. T=0.14
162 5156290180 SHIM ............................................... 1 .................. T=0.16
162 5156290190 SHIM ............................................... 1 .................. T=0.18
162 5156290200 SHIM ............................................... 1 .................. T=0.50
162 5156290380 SHIM ............................................... 1 .................. T=1.00
162 9812250330 SHIM ............................................... 1 .................. T=0.30
162 5156190390 SHIM ............................................... 1 .................. T=0.70
162 5156290900 SHIM ............................................... 1 .................. T=1.40
162 1156390880 SHIM ............................................... 1 .................. T=2.40
176 5156250010 PLATE 2
177 9812250570 PINION 4
178 9812350030 SCREW 4
181 5156190340 SHIM ............................................... 1 .................. T=0.30
181 5156190350 SHIM ............................................... 1 .................. T=0.40
181 5156190360 SHIM ............................................... 1 .................. T=0.50
181 5156190010 SHIM ............................................... 1 .................. T=0.60
181 5156190020 SHIM ............................................... 1 .................. T=0.70
181 5156190030 SHIM ............................................... 1 .................. T=0.80
181 5156190040 SHIM ............................................... 1 .................. T=0.90
181 5156190050 SHIM ............................................... 1 .................. T=1.00
181 5156190070 SHIM ............................................... 1 .................. T=1.10
181 5156190080 SHIM ............................................... 1 .................. T=1.20
181 5156190090 SHIM ............................................... 1 .................. T=1.30
181 5156190100 SHIM ............................................... 1 .................. T=1.40
181 5156190110 SHIM ............................................... 1 .................. T=0.55
181 5156190120 SHIM ............................................... 1 .................. T=0.65
181 5156190130 SHIM ............................................... 1 .................. T=0.75
181 5156190150 SHIM ............................................... 1 .................. T=0.85
181 9812350420 SHIM ............................................... 1 .................. T=0.95
181 9812350430 SHIM ............................................... 1 .................. T=1.05
181 9812350440 SHIM ............................................... 1 .................. T=1.15
181 9812350450 SHIM ............................................... 1 .................. T=1.25
181 5156190250 SHIM ............................................... 1 .................. T=0.20
181 5156190260 SHIM ............................................... 1 .................. T=0.25
181 5156190270 SHIM ............................................... 1 .................. T=0.35
181 5156190370 SHIM ............................................... 1 .................. T=0.45
181 5156191060 SHIM ............................................... 1 .................. T=1.50
181 5156191070 SHIM ............................................... 1 .................. T=1.60
181 5156191080 SHIM ............................................... 1 .................. T=1.35
181 5156191090 SHIM ............................................... 1 .................. T=1.45
181 5156191100 SHIM ............................................... 1 .................. T=1.55
ISUZU 4BG1 GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
ISUZU 4BG1 GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
1 8971621760 GOVERNOR ASSY. ....................1 ...................... INCLUDES. ITEMS W/#
2# 5157210040 HOUSING 1
3# 5157290270 BOLT 6
4# 8913253970 PLATE 1
7# 5157210220 COVER 1
8A# 5157290330 BOLT 4
8B# 5157290540 BOLT 2
11 # 1157290010 GASKET 1
12 # 1157220210 FLYWEIGHT ASSY. 1
13 # 5196190490 KEY 1
15 # 5157290340 WASHER 1
16 # 9813250860 NUT 1
17 # 9813250880 SHIM ............................................1 ...................... T=0.20
17 # 9813255510 SHIM ............................................1 ...................... T=0.30
17 # 9813255520 SHIM ............................................1 ...................... T=0.40
17 # 9813255530 SHIM ............................................1 ...................... T=1.00
17 # 5157292860 SHIM ............................................1 ...................... T=0.50
17 # 5157292870 SHIM ............................................1 ...................... T=1.50
17 # 1157298910 SHIM ............................................1 ...................... T=2.00
17 # 1157298920 SHIM ............................................1 ...................... T=3.00
17 # 1157298930 SHIM ............................................1 ...................... T=4.00
18 # 5157190080 SCREW 1
23 # 1157250110 LINK 1
24 # 9813222350 SPRING 1
25 # 9091854040 RING 1
28 # 5157250420 LEVER 1
34 # 1157232120 SPRING 1
37 # 5157250170 LEVER ASSY. 1
40 # 9813251820 SCREW 1
41 # 1157231860 SPRING CAPSULE 1
43 # 9008130230 NUT 1
45A# 1157256680 LEVER ASSY. 1
45B# 5157250330 LEVER ASSY. 1
59 # 5157210210 COVER 1
60B# 5157290630 BOLT
60C # 9019006160 BOLT 1
63 # 9813919070 GASKET 1
71 # 5157230880 SPRING 1
79 # 1157292940 SHIM ............................................1 ...................... T=0.20
79 # 1157292950 SHIM ............................................1 ...................... T=0.25
79 # 1157292960 SHIM ............................................1 ...................... T=0.30
79 # 1157292970 SHIM ............................................1 ...................... T=0.35
79 # 1157292980 SHIM ............................................1 ...................... T=0.40
79 # 1157292990 SHIM ............................................1 ...................... T=0.50
83 # 9813919060 SEAL 1
86 # 9813254290 BUSHING 1
87 # 9019006160 BOLT 1
90 # 9813251770 SCREW 1
91 # 1157230730 SPRING CAPSULE
ISUZU 4BG1 GOVERNOR COMP. ASSY. (CONT.)
GOVERNOR COMP. ASSY. (CONT.)
ISUZU 4BG1 GOVERNOR COMP. ASSY. (CONT.)
GOVERNOR COMP. ASSY. (CONT.)
93B# 1157296890 NUT 1
93D# 9813261120 NUT 1
93E# 9844100270 NUT 2
94# 5157291230 SCREW 1
96# 5157290530 PLUG 2
99# 9813250620 PIN 1
101# 8941445880 GASKET 2
103# 1157290920 NUT 1
105A# 1157250810 LEVER 1
105D# 8943444370 LEVER 1
105D# 8943444380 LEVER 1
105F # 8970874410 LEVER 1
106# 9813250300 KEY 1
107# 9813254880 WASHER 1
108# 1157293010 COLLAR 1
109# 1157290990 SHIM 1
109# 9813250970 SHIM 1
110# 1157290980 SEAL 1
111# 8970242390 BUSHING 2
112# 9813212050 GASKET 2
113# 9091854150 RING 2
125# 9813252100 CAP 1
150# 9813150650 ADAPTER 1
154# 5157291120 BOLT 1
156# 1835794920 WASHER 1
157# 9019008180 BOLT 1
161# 1157290380 PLUG 1
162# 1157290150 WASHER 1
ISUZU 4BG1 FEED PUMP ASSY.
FEED PUMP ASSY.
ISUZU 4BG1 FEED PUMP ASSY.
FEED PUMP ASSY.
1 8971219100 PUMP ASSY. .................................. 1 ................. INCLUDES ITEMS W/
2 1157610060 PUMP 1
*
3
* 1196230160 GASKET 1
4
* 9813517020 SPRING 2
5
* 1157550020 VALVE 2
8
* 1156190820 BOLT 1
9
* 1157590010 GASKET 4
*
10 1157590030 ADAPTER 1
11
* 5157590270 BOLT 1
13
* 9813550250 RING 1
15
* 5157510120 HOUSING 1
16
* 9813512050 PISTON 1
17
* 9813513020 SPRING 1
18
* 9813550350 GASKET 1
19
* 8941711850 PLUG 1
*
28* 5157540010 TAPPET ASSY. ............................... 1 ................. INCLUDES ITEMS W/#
29 # 9813514030 ROLLER 1
*
30 # 9813514100 PIN 1
*
31 # 1157590020 GUIDE 2
*
ISUZU 4BG1 MISC. INJECTION PUMP ASSY.
MISC. INJECTION PUMP ASSY.
ISUZU 4BG1 MISC. INJECTION PUMP ASSY.
MISC. INJECTION PUMP ASSY.
2 5197510500 BRACKET 1
3 9041010300 STUD 4
8 9091645100 WASHER 4
9 9091506100 WASHER 4
10 5156390020 NUT 4
19 A 5090000841 BOLT ......................................... 6 ........... M8X55 W/LOCK WASHER
19 B 5090002221 BOLT ......................................... 1 ........... M8X22
20 9095720080 GASKET 1
2 8943706750 GASKET 1
ISUZU 4BG1 COUPLING ASSY.
COUPLING ASSY.
ISUZU 4BG1 COUPLING ASSY.
COUPLING ASSY.
1 5157810030 COUPLING 1
4 1156192470 PLATE 1
9 9096620070 BOLT 1
10 9884105020 NUT 1
11 5156190480 WASHER 1
27 5125240210 GEAR 1
30 8944575170 BOLT 6
ISUZU 4BG1 ACCELERATOR PEDAL ASSY.
ACCELERATOR PEDAL ASSY.
ISUZU 4BG1 ACCELERATOR PEDAL ASSY.
ACCELERATOR PEDAL ASSY.
204 A 5197890040 BRACKET 1
ISUZU 4BG1 AIR DUCT ASSY.
AIR DUCT ASSY.
ISUZU 4BG1 AIR DUCT ASSY.
AIR DUCT ASSY.
343 8943216680 HOSE 1
345 8942420340 CLIP 2
ISUZU 4BG1 FUEL SEDIMENTER ASSY.
FUEL SEDIMENTER ASSY.
ISUZU 4BG1 FUEL SEDIMENTER ASSY.
FUEL SEDIMENTER ASSY.
1 1132008410 FUEL SEDIMENTER ................. 1 ................ INCLUDES ITEMS W/%
3% 1132112110 BODY ASSY. 1
4% 5132120591 COVER 1
5% 5096230700 GASKET 1
7% 5132190200 PLUG 1
9% 5096300240 GASKET 1
34% 8944537460 PLUG ......................................... 1 ................ INCLUDES ITEMS W/#
35%# 8944163770 GASKET 1
36% 5132190221 RING 1
38% 5132190210 FLOAT 1
46% 9095720140 GASKET 4
47 894470470 PIPE 1
50B 1097007590 CLIP 2
51B 9097161140 CLIP 3
50C 1097007600 CLIP 2
50C 9097161240 CLIP 3
51 0500406200 BOLT 7
62A 9099063251 BOLT 1
62B 5157590270 BOLT 1
ISUZU 4BG1 CLUTCH ASSY.
CLUTCH ASSY.
ISUZU 4BG1 CLUTCH ASSY.
CLUTCH ASSY.
17 9910664500 BOLT 6
18 9091505140 LOCK WASHER 6
ISUZU 4BG1 SWITCH AND RELAY ASSY.
SWITCH AND RELAY ASSY.
ISUZU 4BG1 SWITCH AND RELAY ASSY.
SWITCH AND RELAY ASSY.
15 1819001372 ENG. STOP ACTUATOR 1
58 1823100080 IGNITION SWITCH ................... 1 ................ INCLUDES ITEM W/%
417 1825500732 EMERGENCY RELAY 1
434% KEYISUZUF KEY 1
Effective: October 1, 2002 TERMS AND CONDITIONS OF SALE PARTS
PAYMENT TERMS 5. Parts must be in new and resalable Rebates for price declines and added charges
Terms of payment for parts are net 10 days. condition, in the original Multiquip pack- for price increases will not be made for stock
age (if any), and with Multiquip part on hand at the time of any price change.
FREIGHT POLICY numbers clearly marked. Multiquip reserves the right to quote and sell
All parts orders will be shipped collect or 6. The following items are not returnable: direct to Government agencies, and to Original
prepaid with the charges added to the invoice. Equipment Manufacturer accounts who use
All shipments are F.O.B. point of origin. a. Obsolete parts. (If an item is in the
price book and shows as being our products as integral parts of their own
Multiquips responsibility ceases when a signed products.
manifest has been obtained from the carrier, replaced by another item, it is
and any claim for shortage or damage must be obsolete.) SPECIAL EXPEDITING SERVICE
settled between the consignee and the carrier. b. Any parts with a limited shelf life A $35.00 surcharge will be added to the invoice
MINIMUM ORDER (such as gaskets, seals, O rings, for special handling including bus shipments,
and other rubber parts) that were insured parcel post or in cases where Multiquip
The minimum charge for orders from Multiquip purchased more than six months must personally deliver the parts to the carrier.
is $15.00 net. Customers will be asked for prior to the return date.
instructions regarding handling of orders not LIMITATIONS OF SELLERS LIABILITY
meeting this requirement. c. Any line item with an extended dealer Multiquip shall not be liable here under for
net price of less than $5.00. damages in excess of the purchase price of the
RETURNED GOODS POLICY
d. Special order items. item with respect to which damages are claimed,
Return shipments will be accepted and credit and in no event shall Multiquip be liable for loss
will be allowed, subject to the following provi- e. Electrical components.
of profit or good will or for any other special,
sions: f. Paint, chemicals, and lubricants. consequential or incidental damages.
1. A Returned Material Authorization must g. Decals and paper products. LIMITATION OF WARRANTIES
be approved by Multiquip prior to ship- h. Items purchased in kits.
ment. No warranties, express or implied, are made in
7. The sender will be notified of any connection with the sale of parts or trade acces-
2. To obtain a Return Material Authorization, material received that is not acceptable. sories nor as to any engine not manufactured
a list must be provided to Multiquip Parts by Multiquip. Such warranties made in connec-
Sales that defines item numbers, quanti- 8. Such material will be held for five
working days from notification, pending tion with the sale of new, complete units are
ties, and descriptions of the items to be made exclusively by a statement of warranty
returned. instructions. If a reply is not received
within five days, the material will be packaged with such units, and Multiquip nei-
a. The parts numbers and descriptions returned to the sender at his expense. ther assumes not authorizes any person to
must match the current parts price assume for it any other obligation or liability
list. 9. Credit on returned parts will be issued at whatever in connection with the sale of its
dealer net price at time of the original products. Apart from such written statement of
b. The list must be typed or computer purchase, less a 15% restocking charge.
generated. warranty, there are no warranties, express,
10. In cases where an item is accepted, for implied or statutory, which extend beyond the
c. The list must state the reason(s) for which the original purchase document description of the products on the face hereof.
the return. can not be determined, the price will be
d. The list must reference the sales based on the list price that was effective
order(s) or invoice(s) under which the twelve months prior to the RMA date.
items were originally purchased. 11. Credit issued will be applied to future
e. The list must include the name and purchases only.
phone number of the person request- PRICING AND REBATES
ing the RMA.
Prices are subject to change without prior
3. A copy of the Return Material Authoriza- notice. Price changes are effective on a spe-
tion must accompany the return shipment. cific date and all orders received on or after
4. Freight is at the senders expense. All that date will be billed at the revised price.
parts must be returned freight prepaid to
Multiquips designated receiving point.
NOTE PAGE
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ Power
1800 Water Ridge Rd. Tel. (800) 883-2551
Suite 500/600 Fax (972) 315-1847
Lewisville, TX 75057
Contact: mqpower@multiquip.com
Web: www.mqpower.com
MQ Parts Department
800-427-1244 Fax: 800-672-7877
310-537-3700 Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
COPYRIGHT 2007, MULTIQUIP INC.

MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other
trademarks are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if
resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the DCA-45SSIU2
WHISPERWATT GENERATOR. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be
considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time
without notice and without incurring any obligations.
Manufactured for
Multiquip Inc.
by
Your Local Dealer is: DENYO CO., LTD, JAPAN

DCA45SSIU2 Rev 7 STD Manual

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

PARTS LIST NO. M1870300034A

To find the latest revision of this

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PAGE 2 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 3

MQ POWER DCA-45SSIU2 ISUZU 4BG1 ENGINE

When ordering parts,

Place Your Parts Order Via Web or Fax

Table 1. Generator Specifications

Armature Connection Star with Neutral Zig Zag

Standby Output 47.7 KVA (38.2 KW) 27.6 KW

Prime Output 45 KVA (36 KW) 2 6 KW

Voltage 240V or 48 0V 240/120V

Speed 1,800 rpm

Power Factor 0.8 1

Aux. AC Power Single Phase, 60 Hz

Voltage 120 VAC

Output 4.8 KW (2.4 KW x 2)

Type 4 Cycle, water-cooled, direct injection

No. of Cylinders 4 cylinders

Bore x Stroke 4.13 in. x 4.92 in. (105 mm x 125 mm)

Rated Output 55.2 HP/1,800 rpm

Displacement 268 cu. in. (4,392 cc)

Coolant Capacity 5.3 gal. (20 liters)

Lube Oil Capacity 3.4 gal. (12.9 liters)

Battery 12V- 100AH

Fue l #2 Diesel Fuel

PAGE 6 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

PAGE 8 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 9

NEVER operate equipment with covers, or

PAGE 10 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

ALWAYS place the engine ON/OFF switch

Over Speed Conditions Sight and Hearing hazard

NEVER tamper with the factory settings of the

Equipment Damage Messages

This generator, other property, or

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 11

PAGE 12 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

ALWAYS allow the machine a proper

NEVER touch output terminals during operation. This is

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 13

PAGE 14 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 15

Figure 3. Typical Generator Grounding Application

PAGE 16 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

When connecting the generator to

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 17

Figure 4. Generator with Trailer

PAGE 18 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 19

Table 2. Trailer Specifications

PAGE 20 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

Table 2. Specifications (Con't)

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 21

PAGE 22 DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07)

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 23

DCA-45SSIU2 FAMILIARIZATION Open Delta Excitation System

Figure 5. Major Components

Table 3. Generator Major Components

DCA-45SSIU2 OPERATION AND PARTS MANUAL (STD) REV. #7 (06/13/07) PAGE 25